Lochinvar Knight 51 Users Manual WBII I O Rev C

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2015-02-09

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WBII-I-O Rev C

Installation & Operation Manual

Models: 51 - 211

This manual must only be used by a

qualified heating installer / service

technician. Read all instructions,

including this manual and the Knight

Wall Mount Service Manual, before

installing. Perform steps in the order

given. Failure to comply could result

in severe personal injury, death, or

substantial property damage.

WARNING

Save this manual for future reference.

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or

to important information concerning the life of the product.

DANGER

WARNING

CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate

injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not

related to personal injury or property damage.

HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3

THE KNIGHT WALL MOUNT BOILER--HOW IT WORKS . . . 4-5

RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1. DETERMINE BOILER LOCATION

Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . . 9

Wall Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Residential Garage Installation . . . . . . . . . . . . . . . . . . . . . 9

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Prevent Combustion Air Contamination . . . . . . . . . . . . . . . 9

Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 10

Using an Existing Vent System to Install a New Boiler . . 10

Removing a Boiler from Existing Common Vent . . . . . . . 11

2. PREPARE BOILER

Remove Boiler from Wood Pallet . . . . . . . . . . . . . . . . . . 12

Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Mounting the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. GENERAL VENTING

Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Install Vent and Combustion Air Piping . . . . . . . . . . . . . . 16

PVC/CPVC Vent Piping Materials . . . . . . . . . . . . . . . 16

Requirements for Installation in Canada . . . . . . . . . . . . . 16

PVC/CPVC Air Intake/Vent Connections . . . . . . . . . . . . . 17

Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Stainless Steel Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Max. Allowable Vent Piping Lengths . . . . . . . . . . . . . . . . 19

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Optional Room Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall . . . . . . . . . . . . . . . . . . . . 21-24

Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

Prepare Wall Penetrations . . . . . . . . . . . . . . . . . . . . . 23

Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 23

Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . . . . 23-24

Sidewall Termination - Optional Concentric Vent . . . . . . 24-26

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical . . . . . . . . . . . . . . . . . . . . . 27-28

Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Prepare Roof Penetrations . . . . . . . . . . . . . . . . . . . . . 28

Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 28

Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . . . . 28

Vertical Termination - Optional Concentric Vent . . . . . . . 29-30

Optional Vertical Concentric Venting . . . . . . . . . . . . . . . . 31-32

6. HYDRONIC PIPING

System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 33

Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . 33

Chilled Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

General Piping Information . . . . . . . . . . . . . . . . . . . . . . . 33

Near Boiler Piping Components . . . . . . . . . . . . . . . . . . . 34

Near Boiler Piping Connections . . . . . . . . . . . . . . . . . . . 35

Circulator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Variable Speed Pump Option . . . . . . . . . . . . . . . . . . . . . 37

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 46

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 47

Natural Gas Supply Pressure Requirements . . . . . . . 47

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 47

Propane Supply Pressure Requirements . . . . . . . . . . 47

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 49

8. FIELD WIRING

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 50

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 50

Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

9. CONDENSATE DISPOSAL

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-60

11. OPERATING INFORMATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 65-66

Knight Wall Mount Boiler Control Module . . . . . . . . . . . . 67

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 68-70

12. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 71-74

13. DIAGRAMS

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Contents

Installation & Operation Manual

Please read before proceeding

Installer – Read all instructions,

including this manual and the Knight

Wall Mount Service Manual, before

installing. Perform steps in the order

given.

User – This manual is for use only by a

qualified heating installer/service

technician. Refer to the User’s

Information Manual for your reference.

Have this boiler serviced/inspected by a

qualified service technician, at least

annually.

Failure to comply with the above could

result in severe personal injury, death or

substantial property damage.

Failure to adhere to the guidelines on this

page can result in severe personal injury,

death, or substantial property damage.

When servicing boiler –

• To avoid electric shock, disconnect electrical supply

before performing maintenance.

• To avoid severe burns, allow boiler to cool before

performing maintenance.

Boiler operation –

• Do not block flow of combustion or ventilation air to

the boiler.

• Should overheating occur or gas supply fail to shut off,

do not turn off or disconnect electrical supply to

circulator. Instead, shut off the gas supply at a location

external to the appliance.

• Do not use this boiler if any part has been under water.

The possible damage to a flooded appliance can be

extensive and present numerous safety hazards. Any

appliance that has been under water must be replaced.

Boiler water –

• Thoroughly flush the system (without boiler

connected) to remove sediment. The high-efficiency

heat exchanger can be damaged by build-up or

corrosion due to sediment.

• Continual fresh make-up water will reduce boiler life.

Mineral buildup in the heat exchanger reduces heat

transfer, overheats the stainless steel heat exchanger,

and causes failure. Addition of oxygen carried in by

makeup water can cause internal corrosion in system

components. Leaks in boiler or piping must be repaired

at once to prevent makeup water.

Freeze protection fluids –

• NEVER use automotive antifreeze. Use only inhibited

propylene glycol solutions, which are specifically

formulated for hydronic systems. Ethylene glycol is

toxic and can attack gaskets and seals used in hydronic

systems.

When calling or writing about the boiler –

Please have the boiler model and serial

number from the boiler rating plate.

Consider piping and installation when

determining boiler location.

Any claims for damage or shortage in

shipment must be filed immediately

against the transportation company by

the consignee.

Factory warranty (shipped with unit)

does not apply to units improperly

installed or improperly operated.

If the information in this manual is not

followed exactly, a fire or explosion may

result causing property damage, personal

injury or loss of life.

This appliance MUST NOT be installed

in any location where gasoline or

flammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do

not use any phone in your building.

• Immediately call your gas supplier

from a near by phone. Follow the

gas supplier’s instructions.

• If you cannot reach your gas supplier,

call the fire department.

• Installation and service must be

performed by a qualified installer,

service agency, or the gas supplier.

WARNING

NOTICE

WARNING

WARNING Do not use petroleum-based cleaning or

sealing compounds in the boiler system.

Gaskets and seals in the system may be

damaged. This can result in substantial

property damage.

CAUTION

CAUTION Do not use “homemade cures” or “boiler

patent medicines”. Serious damage to

the boiler, personnel, and/or property

may result.

Installation & Operation Manual

The Knight Wall Mount Boiler - How it works...

1. Stainless steel heat exchanger

Allows system water to flow through specially designed

coils for maximum heat transfer, while providing

protection against flue gas corrosion. The coils are

encased in a jacket that contains the combustion process.

2. Combustion chamber access cover

Allows access to the combustion side of the heat

exchanger coils.

3. Blower

The blower pulls in air and gas through the venturi (item

5). Air and gas mix inside the blower and are pushed into the

burner, where they burn inside the combustion chamber.

4. Gas valve

The gas valve senses the negative pressure created by the

blower, allowing gas to flow only if the gas valve is

powered and combustion air is flowing.

5. Venturi

The venturi controls air and gas flow into the burner.

6. Flue gas sensor (limit rated)

This sensor monitors the flue gas exit temperature. The control

module will modulate and shut down the boiler if flue gas

temperature gets too hot. This protects the flue pipe from

overheating.

7. Boiler outlet temperature sensor (housed with high

limit sensor)

This sensor monitors boiler outlet water temperature (system

supply). If selected as the controlling sensor, the control

module adjusts boiler firing rate so the outlet temperature is

correct.

8. Boiler inlet temperature sensor

This sensor monitors return water temperature (system

return). If selected as the controlling sensor, the control

module adjusts the boiler firing rate so the inlet temperature is

correct.

9. Temperature and pressure gauge (field installed, not

shown)

Monitors the outlet temperature of the boiler as well as the

system water pressure.

10. Electronic LCD display

The electronic display consists of 4 buttons, a navigation dial

and a multiple line liquid crystal display.

11. Flue pipe adapter

Allows for the connection of the PVC vent pipe system to the

boiler.

12. Burner (not shown)

Made with metal fiber and stainless steel construction,

the burner uses pre-mixed air and gas and provides a

wide range of firing rates.

13. Water outlet (system supply)

The water outlet is the water connection for water leaving the

boiler and entering the system. Boiler connection is 1".

14. Water inlet (system return)

The water inlet is the water connection for water entering the

boiler from the system. Boiler connection is 1".

15. Gas connection pipe

Threaded pipe connection of 1/2". This pipe should be

connected to the incoming gas supply for the purpose of

delivering gas to the boiler.

16. SMART SYSTEM Control Module

The SMART SYSTEM Control responds to internal and

external signals and controls the blower, gas valve, and pumps

to meet the heating demand.

17. Air intake adapter

Allows for the connection of the PVC air intake pipe to

the boiler.

18. High voltage junction box

The junction box contains the connection points for the line

voltage power and all pumps.

19. Manual air vent

Designed to remove trapped air from the heat exchanger

coils.

20. Low voltage connection board

The connection board is used to connect external low voltage

devices.

21. Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage

connection board.

22. Condensate drain connection

Connects the condensate drain line to a 1/2" pipe.

23. Access door

Provides access to all internal components.

24. Ignition electrode

Provides direct spark for igniting the burner.

25. Flame inspection window

The quartz glass window provides a view of the burner

surface and flame.

26. Gas shutoff switch

An electrical switch designed to cut power to the gas valve to

prevent releasing any gas.

27. High limit sensor (housed with outlet sensor)

Device that monitors the outlet water temperature. If the

temperature exceeds its setting, it will break the control circuit,

shutting the boiler down.

28. Relief valve

Protects the heat exchanger from an over pressure condition.

The relief valve provided with the unit is set at 30 psi.

29. Flame sensor

Used by the control module to detect the presence of burner

flame.

30. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

31. Air pressure switch

The air pressure switch detects blocked inlet conditions.

32. Transformer

The transformer provides 24V power to the integrated control.

Installation & Operation Manual

Front View

Left Side (inside unit)

Right Side (inside unit)

The Knight Wall Mount Boiler - How it works... (continued)

FRONT

OF UNIT

Bottom View

Models 51 - 211

Installation & Operation Manual

Ratings

Notes:

1. As an Energy Star Partner, Lochinvar has determined that

Knight wall mount boilers meet the Energy Star guidelines

for energy efficiency.

2. The ratings are based on standard test procedures prescribed

by the United States Department of Energy.

3. Net I=B=R ratings are based on net installed radiation of

sufficient quantity for the requirements of the building and

nothing need be added for normal piping and pickup.

Ratings are based on a piping and pickup allowance of 1.15.

4. Knight wall mount boilers require special gas venting. Use

only the vent materials and methods specified in the Knight

Wall Mount Installation and Operation Manual.

5. Standard Knight wall mount boilers are equipped to operate

from sea level to 4,500 feet only with no adjustments. The

boiler will de-rate by 4% for each 1,000 feet above sea level

up to 4,500 feet.

6. High altitude Knight wall mount boilers are equipped to

operate from 3,000 to 12,000 feet only with no field

adjustments. The boiler will de-rate by 2% for each 1,000

feet above 3,000 feet. High altitude models are

manufactured with a different control module for altitude

operation, but the operation given in this manual remains

the same as the standard boilers. A high altitude label (as

shown in FIG. A) is also affixed to the unit.

Maximum allowed working pressure is located on the rating plate.

NOTICE

Knight Wall Mount Boiler

I=B=R Rating

Model

Number

Note: Change

“N” to “L” for L.P.

gas models.

Input

MBH

(Note 5)

Min Max

Heating

Capacity

MBH

(Note 2, 8

Net

I=B=R

Ratings

Water,

MBH

(Note 3, 8)

AFUE

(Note 1, 8)

WBN051 10 50 45 39 95.3

WBN081 16 80 72 63 95.3

WBN106 21 105 94 82 95.4

WBN151 30 150 135 119 95.5

WBN211 42 210 190 165 95.7

7. The Knight Wall Mount boiler input rate, on some

models, is reduced for vent lengths beyond the

minimum. Models WB(N,L)081 and WB(N,L)106 with

2" vent will reduce 1% for every 10 feet of vent. Models

WB(N,L)151 and WB(N,L)211 with 3" vent will reduce

0.5% for every 10 feet of vent.

8. Ratings have been confirmed by the Hydronics Institute,

Section of AHRI.

9. Knight wall mount boilers comply with the requirements

of CSD-1 Section CW-400 requirements as a temperature

operation control. The manual reset high limit provided

with the Knight is listed to UL353.

Other Specifications

Boiler Water

Content

Gallons

Water

Connections

Gas

Connections

Vent/Air Size

(Note 4)

0.6 1" 1/2" 2"

0.7 1" 1/2" 2"

1.3 1" 1/2" 3"

1.7 1" 1/2" 3"

Figure A High Altitude Label Location

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

The Knight wall mount boiler gas

manifold and controls met safe lighting

and other performance criteria when the

boiler underwent tests specified in ANSI

Z21.13 – latest edition.

Failure to keep boiler area clear and free of

combustible materials, gasoline, and other

flammable liquids and vapors can result in

severe personal injury, death, or

substantial property damage.

Installation must comply with:

• Local, state, provincial, and national codes, laws,

regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1, when

required.

• National Electrical Code.

• For Canada only: B149.1 Installation Code, CSA C22.1

Canadian Electrical Code Part 1 and any local codes.

Before locating the boiler, check:

1. Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations

cannot be avoided, it is recommended that a suitable

drain pan, adequately drained, be installed under the

appliance. The pan must not restrict combustion air

flow. Under no circumstances is the manufacturer to be

held responsible for water damage in connection with

this appliance, or any of its components.

3. Check area around the boiler. Remove any combustible

materials, gasoline and other flammable liquids.

4. The Knight wall mount boiler must be installed so that

gas control system components are protected from

dripping or spraying water or rain during operation or

service.

5. If a new boiler will replace an existing boiler, check for

and correct system problems, such as:

• System leaks causing oxygen corrosion or heat

exchanger cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Lack of freeze protection in boiler water causing system

and boiler to freeze and leak.

WARNING This appliance is certified as an indoor

appliance. Do not install the appliance

outdoors or locate where the appliance will

be exposed to freezing temperatures or to

temperatures that exceed 100°F.

Failure to install the appliance indoors

could result in severe personal injury,

death, or substantial property damage.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1" from combustible materials.

2. Vent pipe – at least 1" from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance

minimums.

Clearances for service access

1. See FIG.’s 1-1 and 1-2 on page 8 for recommended

service clearances. If you do not provide the minimum

clearances shown, it may not be possible to service the

boiler without removing it from the space.

Closet and alcove installations

This appliance requires a special venting

system. The vent connection to the

appliance is made of CPVC. Field supplied

vent fittings must be cemented to the

CPVC fitting on the boiler. Use only the

vent materials, primer, and cement

specified in the manual to make the vent

connections. Failure to follow this

warning could result in fire, personal

injury, or death.

For closet and alcove installations as

shown in FIG.’s 1-1 and 1-2, CPVC or

stainless steel vent material must be used

inside the structure. The two ventilating

air openings shown in FIG. 1-1 are

required for this arrangement. Failure to

follow this warning could result in fire,

personal injury, or death.

WARNING

NOTICE

WARNING

A closet is any room the boiler is installed in which is less than

79 cubic feet for WBN051 through WBN106 models,

104 cubic feet for WBN151 models, and 125 cubic feet for

WBN211 models.

An alcove is any room which meets the criteria for a closet

with the exception that it does not have a door.

Example: Room dimensions = 4 feet long, 4 feet wide, and

9 foot ceiling = 4 x 4 x 9 = 144 cubic feet. This would be

considered a closet for a Knight wall mount boiler.

1 Determine boiler location

Installation & Operation Manual

TOP

6" MINIMUM

LEFT

24" SERVICE

0" MINIMUM

FRONT

24" SERVICE

6" MINIMUM

BOTTOM

24" SERVICE

0" MINIMUM

1" MINIMUM CLEARANCE

AROUND HOT WATER PIPES

1" MINIMUM CLEARANCE

ROUND VENT PIPE OPEN FRONT

RIGHT

0" MINIMUM

Figure 1-2 Alcove Installation - Minimum Required Clearances

TOP

6" MINIMUM

LEFT

24" SERVICE

0" MINIMUM

BOTTOM

24" SERVICE

0" MINIMUM

1" MINIMUM CLEARANCE

AROUND HOT WATER PIPES

1" MINIMUM CLEARANCE

ROUND VENT PIPE CLOSED DOOR

FRONT

24" SERVICE

6" MINIMUM

VENTILATING

AIR OPENING*

*AREA OF EACH OPENING:

1 SQ. INCH PER 1000 BTU PER HOUR INPUT

WITH A MINIMUM OF 100 SQ. INCHES.

VENTILATING

AIR OPENING*

RIGHT

0" MINIMUM

Figure 1-1 Closet Installation - Minimum Required Clearances

WARNING For closet installations, CPVC or

stainless steel vent material MUST

BE used in a closet structure due to

elevated temperatures. Failure to

follow this warning could result in

fire, personal injury, or death.

Note: Service clearances are recommendations only.

WARNING For alcove installations, CPVC or

stainless steel vent material MUST

BE used in an alcove structure due

to elevated temperatures. Failure

to follow this warning could result

in fire, personal injury, or death.

1 Determine boiler location

Installation & Operation Manual

Provide air openings to room:

Knight wall mount boiler alone in boiler room

1. No air ventilation openings into the boiler room are

needed when clearances around the Knight wall mount

boiler are at least equal to the SERVICE clearances

shown in FIG.’s 1-1 and 1-2. For spaces that do NOT

supply this clearance, provide two openings as shown

in FIG. 1-1. Each opening must provide one square

inch free area per 1,000 Btu/hr of boiler input.

Knight wall mount boiler in same space with other

gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA

B149.1 (Canada) to size/verify size of the

combustion/ventilation air openings into the space.

The space must be provided with

combustion/ventilation air openings

correctly sized for all other appliances

located in the same space as the Knight

wall mount boiler.

Do not install the boiler in an attic.

Failure to comply with the above

warnings could result in severe personal

injury, death, or substantial property

damage.

2. Size openings only on the basis of the other appliances

in the space. No additional air opening free area is

needed for the Knight wall mount boiler because it

takes its combustion air from outside (direct vent

installation).

Wall mounting location

Ensure the wall for which the boiler is intended to be

mounted is comprised of either, cement, brick, block, or

wooden studs spaced 16" apart from center. Ensure the wall

is capable of supporting at least 200 pounds.

If flooding is possible, elevate the boiler sufficiently to

prevent water from reaching the boiler.

Ensure the boiler is installed in a location that minimizes

the risk of water damage due to valves, pumps, etc.

Residential garage installation

Precautions

Take the following precautions when installing the appliance in

a residential garage. If the appliance is located in a residential

garage, it should be installed in compliance with the latest

edition of the National Fuel Gas Code, ANSI Z223.1 and/or

CAN/CGA-B149 Installation Code.

• Appliances located in residential garages and in

adjacent spaces that open to the garage and are not part

of the living space of a dwelling shall be installed so that

all burners and burner ignition devices are located not

less than 18 inches (46 cm) above the floor.

• The appliance shall be located or protected so that it is

not subject to physical damage by a moving vehicle.

Vent and air piping

The Knight wall mount boiler requires a special vent system,

designed for pressurized venting.

The boiler is to be used for either direct vent installation or for

installation using indoor combustion air. When room air is

considered, see Section 3, General Venting. Note prevention of

combustion air contamination below when considering vent/air

termination.

Vent and air must terminate near one another and may be

vented vertically through the roof or out a side wall, unless

otherwise specified. You may use any of the vent/air piping

methods covered in this manual. Do not attempt to install the

Knight wall mount boiler using any other means.

Be sure to locate the boiler such that the vent and air piping can

be routed through the building and properly terminated. The

vent/air piping lengths, routing and termination method must

all comply with the methods and limits given in this manual.

Prevent combustion air contamination

Install air inlet piping for the Knight wall mount boiler as

described in this manual. Do not terminate vent/air in locations

that can allow contamination of combustion air. Refer to Table

1A, page 10 for products and areas which may cause

contaminated combustion air.

You must pipe combustion air to the boiler

air intake. Ensure that the combustion air

will not contain any of the contaminants in

Table 1A, page 10. Contaminated

combustion air will damage the boiler,

resulting in possible severe personal injury,

death or substantial property damage. Do

not pipe combustion air near a swimming

pool, for example. Also, avoid areas subject

to exhaust fumes from laundry facilities.

These areas will always contain

contaminants.

WARNING

1 Determine boiler location (continued)

Installation & Operation Manual

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents

found in household laundry rooms

Adhesives used to fasten building products and other

similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Table 1A Corrosive Contaminants and Sources

Failure to follow all instructions can result

in flue gas spillage and carbon monoxide

emissions, causing severe personal injury

or death.

WARNING

When using an existing vent system to

install a new boiler:

Check the following venting components before installing:

•Material- For materials listed for use with this appliance,

see Section 3 - General Venting, Table 3A. For stainless

steel venting, an adapter of the same manufacturer

(Table 3B) must be used at the flue collar connection.

•Size- To ensure proper pipe size is in place, see Table 3C.

Check to see that this size is used throughout the vent

system.

• Manufacturer - For a stainless steel application, you

must use only the listed manufacturers and their type

product listed in Table 3A for CAT IV positive pressure

venting with flue producing condensate.

•Supports- Non-combustible supports must be in place

allowing a minimum 1/4" rise per foot. The supports

should adequately prevent sagging and vertical slippage,

by distributing the vent system weight. For additional

information, consult the vent manufacturer’s

instructions for installation.

• Terminations - Carefully review Sections 3 through 5 to

ensure requirements for the location of the vent and air

terminations are met and orientation of these fit the

appropriate image from the Sidewall or Vertical

options listed in the General Venting Section. For

stainless steel vent, only use terminations listed in Table

3B for the manufacturer of the installed vent.

•Seal- With prior requirements met, the system should be

tested to the procedure listed in parts (c) through (f) of

the Removal of an Existing Boiler Section on page 11.

With stainless steel vent, seal and connect all pipe and

components as specified by the vent manufacturer used; with

PVC/CPVC vent, see the Installing Vent or Air Piping Section

on page 16.

WARNING If any of these conditions are not met, the

existing system must be updated or

replaced for that concern. Failure to

follow all instructions can result in flue gas

spillage and carbon monoxide emissions,

causing severe personal injury or death.

1 Determine boiler location

Installation & Operation Manual

When removing a boiler from existing

common vent system:

Do not install the Knight wall mount boiler

into a common vent with any other

appliance. This will cause flue gas spillage or

appliance malfunction, resulting in possible

severe personal injury, death, or substantial

property damage.

Failure to follow all instructions can result in

flue gas spillage and carbon monoxide

emissions, causing severe personal injury or

death.

At the time of removal of an existing boiler, the following steps

shall be followed with each appliance remaining connected to

the common venting system placed in operation, while the other

appliances remaining connected to the common venting system

are not in operation.

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion, or other deficiencies, which

could cause an unsafe condition.

c. Test vent system – Insofar as is practical, close all building

doors and windows and all doors between the space in

which the appliances remaining connected to the common

venting system are located and other spaces of the building.

Turn on clothes dryers and any appliance not connected to

the common venting system. Turn on any exhaust fans,

such as range hoods and bathroom exhausts, so they will

operate at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance

will operate continuously.

e. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame of a

match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance remaining

connected to the common venting system properly vents

when tested as outlined herein, return doors, windows,

exhaust fans, fireplace dampers, and any other gas-burning

appliance to their previous conditions of use.

DANGER

WARNING

g. Any improper operation of the common venting system

should be corrected so the installation conforms with

the National Fuel Gas Code, ANSI Z223.1/NFPA 54

and/or CAN/CSA B149.1, Natural Gas and Propane

Installation Code. When resizing any portion of the

common venting system, the common venting system

should be resized to approach the minimum size as

determined using the appropriate tables in Part 11 of the

National Fuel Gas Code, ANSI Z223.1/NFPA and/or

CAN/CSA B149.1, Natural Gas and Propane Installation

Code.

1 Determine boiler location

Installation & Operation Manual

2 Prepare boiler

Remove boiler from wood pallet

1. After removing the outer shipping carton from the boiler,

remove the parts box.

2. To remove the boiler from the pallet:

a. Remove the two (2) lag bolts securing the bottom

of the unit to the pallet.

b. Lift the boiler off the wall bracket mounted to

the pallet.

3. Remove the two (2) lag bolts securing the wall bracket to

the wood pallet. Be certain not to lose the wall bracket as

it will be needed for securing the boiler to the wall

(FIG. 2-1).

Do not drop the boiler or bump the jacket

on the floor or pallet. Damage to the

boiler can result.

The gas conversion procedure should be

accomplished BEFORE the boiler is

installed. For a boiler already installed,

you must turn off gas supply, turn off

power, and allow the boiler to cool before

proceeding. You must also completely test

the boiler after conversion to verify

performance as described under Start-up,

Section 10 of this manual.

You must install the propane orifice to fire

the Knight wall mount boiler on propane.

Verify when installing that the orifice size

marking matches boiler size (Table 2A).

Failure to comply could result in severe

personal injury, death, or substantial

property damage.

1. Remove the front access cover from the unit (no tools

required for removal).

2. Disconnect the ribbon cable from the control board.

Remove the four (4) screws securing the bezel to the front of

the unit and remove the bezel.

3. Locate the power switch on the gas valve and turn the power

switch to the “OFF” position (FIG. 2-2).

4. Disconnect the Molex plug from the wiring connector

located on the gas valve.

5. Using a 5/16" nut driver, loosen the band clamp securing the

air intake coupler to the gas valve venturi. Remove the air

intake pipe and coupler from the gas valve venturi.

6. Using a 4mm Allen wrench, remove the two (2) screws

securing the gas valve venturi to the inlet of the combustion

blower (FIG. 2-2). Remove the gas valve venturi assembly

from the unit.

DO NOT DISCARD-

WILL BE NEEDED TO

SECURE THE BOILER

TO THE WALL

REMOVE SHIPPING

[WALL] BRACKET

Figure 2-1 Boiler Mounted on Shipping Pallet

Gas conversions

LP Conversion Table

Model LP Orifice Stamping

51 50

81 80

106 105

151 210 / W150

211 210 / W150

NOTICE

WARNING

Table 2A LP Conversion Table

Figure 2-2 Gas Valve Power Switch & Venturi Removal

DETAIL

POWER SWITCH

REMOVE THE TWO (2) SCREWS

SECURING THE GAS VALVE VENTURI

TO THE INLET OF THE COMBUSTION BLOWER

7. Using a 4mm Allen wrench, remove the four (4) screws

securing the gas valve to the venturi (FIG. 2-3).

8. Locate the propane orifice disk from the conversion kit bag.

Verify that the stamping on the orifice disk matches the

boiler size (51 - 211, see Table 2A).

9. Place the orifice into the black rubber grommet in the side of

the gas valve and secure inside the gas valve (see FIG. 2-3).

10. Reposition the gas valve against the venturi and replace the

four (4) screws removed in Step 7, securing the valve to the

venturi (FIG. 2-3).

11. Reposition the gas valve venturi assembly inside the unit.

Secure the gas valve venturi to the combustion blower by

replacing the two (2) screws removed in Step 6 (FIG. 2-2).

12. Reattach the air intake pipe and coupler to the gas valve

venturi. Tighten the band clamp to secure.

Installation & Operation Manual

2 Prepare boiler (continued)

FASTENERS

APPROPRIATE

FOR WALL TYPE

QTY: 4

MOUNTING BRACKET

(FACTORY SUPPLIED)

WALL:

WOOD OR METAL STUDS ON

16" CENTERS

-OR-

MASONRY / POURED CONCRETE

Figure 2-4 Mounting the Boiler

Figure 2-3 Installing Propane Orifice

13. Reattach the wiring connector to the gas valve. Tighten

the screw on the wiring connector to secure to the gas

valve.

14. Turn the gas valve power switch to the “ON” position.

15. Reattach the bezel to the unit. Reconnect the ribbon cable

to the control board.

16. After installation is complete, fill out the gas conversion

label (in the conversion kit bag) and affix it to the unit

under the boiler rating plate inside the unit. Attach the LP

caution label (in the conversion kit bag) to the left side of

the unit in the lower left corner.

17. Replace the front access cover.

2. Mount the wall bracket using the 2 1/4" lag bolts

provided. Make sure the top edge of the bracket is away

from the wall. Ensure the bracket is level when mounted.

Extreme care is needed to ensure the bolts are secured in

the center of the studs.

3. Hang the boiler on the bracket and secure the bottom of

the boiler with two (2) additional lag bolts provided.

Mounting to a metal studded wall:

1. The wall mount bracket is designed for a stud spacing of

16 inches from center. For other stud spacing a solid

mounting surface must be provided by the installer.

WARNING The boiler is too heavy for a single person to

lift. A minimum of two people is needed for

mounting the boiler onto the bracket.

2. Mount the wall bracket using two (2) field supplied toggle

bolts capable of supporting 100 pounds each. Ensure the

top edge of the bracket is away from the wall. Ensure the

bracket is level when mounted. Extreme care is needed to

ensure the bolts are secured in the center of the studs.

3. Hang the boiler on the bracket and secure the bottom of the

boiler with two (2) field supplied toggle bolts.

WARNING Do not mount the boiler to a hollow wall. Be

sure to mount the boiler to the studs only.

Mounting the boiler

See page 9 of this manual for boiler mounting location

instructions.

NOTICE The Knight Wall Mount boiler is not

intended for floor installation.

Mounting to a wood studded wall:

1. The wall mount bracket is designed for a stud spacing of

16 inches from center. For other stud spacing a solid

mounting surface must be provided by the installer.

WARNING Do not mount the boiler to a hollow wall.

Be sure to mount the boiler to the studs

only.

Mounting to a concrete wall:

1. Mount the wall bracket using the two (2) wedge anchor

bolts provided with the bracket. To mount the wedge

anchor bolts, drill a 1/4" diameter hole 1 1/8" deep and

insert anchor. Hang the bracket from the anchor and secure

with the two nuts provided. Make sure the top edge of the

bracket is away from the wall. Ensure bracket is level when

mounted. Extreme care is needed to ensure the bolts are

secured in the center of the studs.

Note: If wall thickness does not allow a 1 1/8" deep hole, field

supplied hardware suitable for the application should be

provided.

2. Hang the boiler on the bracket and secure the bottom of the

boiler with two (2) remaining anchors, following the

instructions above.

WARNING The boiler is too heavy for a single person to

lift. A minimum of two people is needed for

mounting the boiler onto the bracket.

WARNING After converting to LP, check combustion

per the Start-up procedure in Section 10

of this manual. Failure to check and

verify combustion could result in severe

personal injury, death, or substantial

property damage.

WARNING The boiler is too heavy for a single person to

lift. A minimum of two people is needed for

mounting the boiler onto the bracket.

3 General venting

Figure 3-1 PVC/CPVC Two-Pipe Sidewall

Termination - See page 21 for more details

Figure 3-3 PVC/CPVC Concentric Sidewall

Termination - See page 24 for more details

Direct venting options - Sidewall Vent

Figure 3-2 Stainless Steel Two-Pipe Sidewall

Termination - See page 22 for more details

Installation & Operation Manual

Figure 3-4 PVC/CPVC Two-Pipe

Vertical Termination - See page 27

for more details

Figure 3-5 Stainless Steel Two-Pipe

Vertical Termination - See page 27

for more details

Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air Figure 3-8 Stainless Steel Vertical Vent, Sidewall Air

Direct venting options - Vertical Vent

Direct venting options - Vertical Vent, Sidewall Air

Stainless steel vent/air design and terminations will vary slightly by manufacturer.

NOTICE

Figure 3-6 PVC/CPVC Concentric

Vertical Termination - See page 29

for more details

3 General venting (continued)

Installation & Operation Manual

3 General venting

PVC/CPVC Vent piping materials

Use only the materials listed in Table 3A for

vent pipe, and fittings. Failure to comply

could result in severe personal injury, death,

or substantial property damage.

Installation must comply with local

requirements and with the National Fuel Gas

Code, ANSI Z223.1 for U.S. installations or

CSA B149.1 for Canadian installations.

Install vent and combustion air piping

DANGER The Knight wall mount boiler must be

vented and supplied with combustion and

ventilation air as described in this section.

Ensure the vent and air piping and the

combustion air supply comply with these

instructions regarding vent system, air

system, and combustion air quality. See also

Section 1 of this manual.

Inspect finished vent and air piping

thoroughly to ensure all are airtight and

comply with the instructions provided and

with all requirements of applicable codes.

Failure to provide a properly installed vent

and air system will cause severe personal

injury or death.

All PVC vent pipes must be glued, properly

supported, and the exhaust must be pitched

a minimum of a 1/4 inch per foot back to the

boiler (to allow drainage of condensate).

WARNING

NOTICE

WARNING

WARNING For closet and alcove installations, CPVC or

stainless steel material MUST BE used in a

closet/alcove structure. Failure to follow this

warning could result in fire, personal injury,

or death.

NOTICE

Requirements for installation in

Canada

1. Installations must be made with a vent pipe system

certified to ULC-S636.

IPEX is an approved vent manufacturer in Canada

supplying vent material listed to ULC-S636.

2. The first three (3) feet of plastic vent pipe from the

appliance flue outlet must be readily accessible for visual

inspection.

3. The components of the certified vent system must not be

interchanged with other vent systems or unlisted

pipe/fittings.

4. The 2" and 3" Concentric Vent Kits available from

Lochinvar (see Section 4 – Sidewall Termination – Optional

Concentric Vent) and the 2" and 3" Concentric Vent Kits

available from IPEX are approved for use on the Knight

wall mount boiler. Both kits are listed to the ULC-S636

standard for use in Canada.

For models 50 - 105 when transitioning

from 2 to 3 inch vent diameter, a 2" pipe

section and 2" to 3" increaser are required

to be CPVC when PVC/CPVC vent is used.

For installations using 2" vent, the first

seven (7) equivalent feet of vent must be

CPVC (field supplied). See examples below.

WARNING

Examples: 1. Seven (7) feet vertical

2. Connector + 90° elbow + 2 feet horizontal

3. One (1) foot vertical + 90° elbow + 1 foot

horizontal

This appliance requires a special venting

system. The vent connection to the

appliance must be made with the starter

CPVC pipe section provided with the

appliance if PVC/CPVC vent is to be used.

For stainless steel venting use an adapter

from Table 3B (page 18) that corresponds

with the intended vent manufacturer to be

used and discard the CPVC starter piece.

The field provided vent fittings must be

cemented to the CPVC pipe section using an

“All Purpose Cement” suitable for PVC and

CPVC pipe. Use only the vent materials,

primer, and cement specified in this manual

to make the vent connections. Failure to

follow this warning could result in fire,

personal injury, or death.

Installing vent and air piping

Improper installation of PVC or CPVC

systems may result in injury or death.

CAUTION

Use only cleaners, primers, and solvents that

are approved for the materials which are

joined together.

NOTICE

1. Work from the boiler to vent or air termination. Do not

exceed the lengths given in this manual for the air or vent

piping.

2. Cut pipe to the required lengths and deburr the inside and

outside of the pipe ends.

3. Chamfer outside of each pipe end to ensure even cement

distribution when joining.

4. Clean all pipe ends and fittings using a clean dry rag.

(Moisture will retard curing and dirt or grease will prevent

adhesion.)

WARNING Insulation should not be used on PVC or

CPVC venting materials. The use of

insulation will cause increased vent wall

temperatures, which could result in vent

pipe failure.

3 General venting (continued)

Table 3A Vent Pipe, and Fittings

5. Dry fit vent or air piping to ensure proper fit up before

assembling any joint. The pipe should go a third to

two-thirds into the fitting to ensure proper sealing after

cement is applied.

6. Priming and Cementing:

a. Handle fittings and pipes carefully to prevent

contamination of surfaces.

b. Apply a liberal even coat of primer to the fitting

socket.

c. Apply a liberal even coat of primer to the pipe end to

approximately 1/2" beyond the socket depth.

d. Apply a second primer coat to the fitting socket.

e. While primer is still wet, apply an even coat of

approved cement to the pipe equal to the depth of

the fitting socket.

f. While primer is still wet, apply an even coat of

approved cement to the fitting socket.

g. Apply a second coat of cement to the pipe.

h. While the cement is still wet, insert the pipe into the

fitting, if possible twist the pipe a 1/4 turn as you insert

it. NOTE: If voids are present, sufficient cement was

not applied and joint could be defective.

i. Wipe excess cement from the joint removing ring or

beads as it will needlessly soften the pipe.

PVC/CPVC air intake/vent connections

1. Combustion Air Intake Connector (FIG. 3-9) - Used to provide combustion air directly to the unit from outdoors. A fitting

is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National

Mechanical Code, Section 305, Table 305.4 or as local codes dictate.

2. Vent Connector (FIG. 3-9) - Used to provide a passageway for conveying combustion gases to the outside. A transition

fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section

305, Table 305.4 or as local codes dictate.

VENT

AIR

Figure 3-9 Near Boiler PVC/CPVC Venting

Air inlet pipe materials:

The air inlet pipe(s) must be sealed. Choose acceptable

combustion air inlet pipe materials from the following list:

PVC, CPVC or ABS

Dryer Vent or Sealed Flexible Duct (not recommended

for rooftop air inlet)

Galvanized steel vent pipe with joints and seams sealed as

specified in this section.

Type “B” double-wall vent with joints and seams sealed as

specified in this section.

AL29-4C, stainless steel material to be sealed to

specification of its manufacturer.

*Plastic pipe may require an adapter (not provided) to

transition between the air inlet connection on the appliance and

the plastic air inlet pipe.

All vent pipe materials and fittings must comply with the following:

Item Material Standards for installation in:

United States Canada

Vent pipe and fittings

PVC schedule 40 ANSI/ASTM D1785 CPVC and PVC venting must be ULC-

S636 Certified. IPEX is an approved

manufacturer in Canada supplying vent

material listed to ULC-S636.

PVC-DWV ANSI/ASTM D2665

CPVC schedule 40/80 ANSI/ASTM F441

AL29-4C UL1738 ULC-S636

Pipe cement/primer PVC ANSI/ASTM D2564 IPEX System 636

Cements & Primers

CPVC ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

Approved Stainless Steel Vent Manufacturers

Make Model

ProTech Systems (Simpson Dura-Vent Co.) FasNSeal Vent / FasNSeal Flex* Vent

Z-Flex (Nova Flex Group) Z-Vent

Heat Fab (Selkirk Corporation) Saf-T Vent

*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure

no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method,

see manufacturer’s instructions.

Installation & Operation Manual

3 General venting

Sealing of Type “B” double-wall vent material or galvanized

vent pipe material used for air inlet piping on a sidewall or

vertical rooftop Combustion Air Supply System:

a. Seal all joints and seams of the air inlet pipe using either

Aluminum Foil Duct Tape meeting UL Standard 723 or

181A-P or a high quality UL Listed silicone sealant such as

those manufactured by Dow Corning or General Electric.

b. Do not install seams of vent pipe on the bottom of

horizontal runs.

c. Secure all joints with a minimum of three sheet metal

screws or pop rivets. Apply Aluminum Foil Duct Tape or

silicone sealant to all screws or rivets installed in the vent

pipe.

d. Ensure that the air inlet pipes are properly supported.

The PVC, CPVC, or ABS air inlet pipe should be cleaned and

sealed with the pipe manufacturer’s recommended solvents

and standard commercial pipe cement for the material used.

The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe

should use a silicone sealant to ensure a proper seal at the

appliance connection and the air inlet cap connection. Dryer

vent or flex duct should use a screw type clamp to seal the vent

to the appliance air inlet and the air inlet cap. Proper sealing

of the air inlet pipe ensures that combustion air will be free of

contaminants and supplied in proper volume.

When a sidewall or vertical rooftop combustion air supply

system is disconnected for any reason, the air inlet pipe must

be resealed to ensure that combustion air will be free of

contaminants and supplied in proper volume.

DANGER Failure to properly seal all joints and seams

as required in the air inlet piping may

result in flue gas recirculation, spillage of

flue products and carbon monoxide

emissions causing severe personal injury

or death.

Stainless steel vent

This product has been approved for use with stainless steel

using the manufacturers listed in Table 3A.

Use only the materials, vent systems, and

terminations listed in Table 3B. DO NOT

mix vent systems of different types or

manufacturers, unless listed in this manual.

Failure to comply could result in severe

personal injury, death, or substantial

property damage.

WARNING

Installations must comply with applicable

national, state, and local codes. Stainless

steel vent systems must be listed as a

UL-1738 approved system for the United

States and a ULC-S636 approved system for

Canada.

NOTICE

Installation of a stainless steel vent system

should adhere to the stainless steel vent

manufacturer’s installation instructions

supplied with the vent system.

NOTICE

The installer must use a specific vent starter

adapter at the flue collar connection,

supplied by the vent manufacturer to adapt

to its vent system. See Table 3B for approved

vent adapters. Discard CPVC starter piece.

NOTICE

Table 3B Approved Stainless Steel Terminations and Adapters

Model

ProTech Heat Fab Z Flex

FasNSeal Saf-T Vent Z-Vent

**Boiler

Adapter

Flue

Termination

Intake

Air

Termination

**Boiler

Adapter

Intermediate

Adapter

Flue

Termination

Intake

Air

Termination

**Boiler

Adapter

Flue

Termination

Intake Air

Termination

51 - 211

300716

(Vent)

300715

(Intake Air)

FSBS3

FSRC3(R.C) 303889

WB50210

(Vent)

KB80210

(Intake Air)

9353BUREZ-1* 9392

5300CI 9314TERM

2SVSLPVC3

(Vent)

2SVSLA03

(Intake Air)

2SVSTP03

2SVSRCX03 2SVSTEX0390

* = This adapter must be used in addition to the boiler adapter for Saf-T vent pipe as shown in FIG. 3-10, unless approved vent

other than standard diameter is used. Consult a Heat Fab representative for questions.

**The stainless steel venting option is only available in 3" vent diameters.

WARNING Using vent or air intake materials other

than those specified, failure to properly

seal all seams and joints or failure to follow

vent pipe manufacturer’s instructions can

result in personal injury, death or property

damage. Mixing of venting materials will

void the warranty and certification of the

appliance.

NOTICE The use of double-wall vent or insulated

material for the combustion air inlet pipe

is recommended in cold climates to

prevent the condensation of airborne

moisture in the incoming combustion air.

3 General venting (continued)

Removing from existing vent

Follow the instructions in Section 1, page 11 of this manual

when removing a boiler from an existing vent system.

Vent and air piping

Vent and air system:

Installation must comply with local

requirements and with the National Fuel Gas

Code, ANSI Z223.1 for U.S. installations or

CSA B149.1 for Canadian installations.

You must also install air piping from outside to the boiler air

intake adapter. The resultant installation is direct vent (sealed

combustion).

You may use any of the vent/air piping methods covered in this

manual. Do not attempt to install the Knight wall mount boiler

using any other means.

NOTICE

WARNING

VENT

3" S.S. INTERMEDIATE

(FOR SAF-T VENT ONLY)

3" S.S. ADAPTER

Figure 3-10 Near Boiler Stainless Steel Venting

Stainless steel air intake/vent

connections

1. Combustion Air Intake Connector (FIG. 3-10) - Used

to provide combustion air directly to the unit from

outdoors. A fitting is provided on the unit for final

connection. Combustion air piping must be supported

per guidelines listed in the National Mechanical Code,

Section 305, Table 305.4 or as local codes dictate.

2. Vent Connector (FIG. 3-10) - Used to provide a

passageway for conveying combustion gases to the

outside. A transition fitting is provided on the unit for

final connection. Vent piping must be supported per the

National Building Code, Section 305, Table 305.4 or as

local codes dictate.

Maximum allowable combustion air and

vent piping lengths are as follows:

Model 2" Max Vent/Air 3" Max Vent/Air

51 40 feet 100 feet

81 40 feet 100 feet

106 40 feet 100 feet

151 N/A 100 feet

211 N/A 100 feet

Increasing or decreasing the size of the

combustion air or vent piping beyond the

sizes listed in Table 3C is not authorized.

NOTICE

When determining equivalent combustion air and vent length,

add 5 feet for each 90° elbow, 3 feet for each 45° elbow, and 3 feet

for the concentric vent kit, see example below.

EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45°

elbows + (1) concentric vent kit = 49 equivalent feet of piping.

Table 3C Maximum Combustion Air and Vent Piping

Lengths

Note: The minimum combustion air and vent piping length is

12 equivalent feet.

For 2" vent / air lengths greater than 40 feet,

consult the factory.

NOTICE

The Knight wall mount boiler uses model specific

combustion air intake and vent piping sizes as detailed in

Table 3C below.

Vent, air piping and termination:

The Knight wall mount boiler vent and air piping can be

installed through the roof or through a sidewall. Follow the

procedures in this manual for the method chosen. Refer to the

information in this manual to determine acceptable vent and air

piping length.

DO NOT mix components from different

systems. The vent system could fail, causing

leakage of flue products into the living space.

Use only approved stainless steel, PVC or

CPVC pipe and fittings. For PVC/CPVC use

with primer and cement specifically

designed for the material used.

Installation & Operation Manual

Air contamination

Pool and laundry products and common household and

hobby products often contain fluorine or chlorine

compounds. When these chemicals pass through the boiler,

they can form strong acids. The acid can eat through the

boiler wall, causing serious damage and presenting a possible

threat of flue gas spillage or boiler water leakage into the

building.

If the boiler combustion air inlet is located

in a laundry room or pool facility, for

example, these areas will always contain

hazardous contaminants.

To prevent the potential of severe personal

injury or death, check for areas and

products listed in Table 1A, page 10 before

installing the boiler or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently.

—OR—

• Relocate air inlet and vent

terminations to other areas.

WARNING

Optional room air

Commercial applications utilizing the Knight wall mount

boiler may be installed with a single pipe carrying the flue

products to the outside while using combustion air from the

equipment room. In order to use the room air venting option

the following conditions and considerations must be

followed.

• The unit MUST be installed with the appropriate

room air kit (Table 3D).

• The equipment room MUST be provided with

properly sized openings to assure adequate

combustion air. Please refer to instructions provided

with the room air kit.

• There will be a noticeable increase in the noise level

during normal operation from the inlet air opening.

• Using the room air kit makes the unit vulnerable to

combustion air contamination from within the

building. Please review Section 1, Prevent

Combustion Air Contamination, to ensure proper

installation.

• Vent system and terminations must comply with the

standard venting instructions set forth in this

manual.

WARNING When utilizing the single pipe method,

provisions for combustion and ventilation

air must be in accordance with Air for

Combustion and Ventilation, of the latest

edition of the National Fuel Gas Code,

ANSI Z223.1, in Canada, the latest edition

of CGA Standard B149 Installation Code

for Gas Burning Appliances and

Equipment, or applicable provisions of the

local building codes.

Model Kit Number

51 - 211 KIT30051

Table 3D Optional Room Air Kit

NOTICE Optional room air is intended for

commercial applications. Combustion air

piping to the outside is recommended for

residential applications.

Please read the information given in Table 1A, page 10, listing

contaminants and areas likely to contain them. If

contaminating chemicals will be present near the location of the

boiler combustion air inlet, have your installer pipe the boiler

combustion air and vent to another location, per this manual.

3 General venting

Installation & Operation Manual

4 Sidewall direct venting

Vent/air termination – sidewall

Follow instructions below when

determining vent location to avoid

possibility of severe personal injury, death,

or substantial property damage.

A gas vent extending through an exterior

wall shall not terminate adjacent to a wall

or below building extensions such as eaves,

parapets, balconies, or decks. Failure to

comply could result in severe personal

injury, death, or substantial property

damage.

Installation must comply with local

requirements and with the National Fuel

Gas Code, ANSI Z223.1 for U.S.

installations or CSA B149.1 for Canadian

installations.

WARNING

NOTICE

WARNING Do not connect any other appliance to the

vent pipe or multiple boilers to a common

vent pipe. Failure to comply could result in

severe personal injury, death, or substantial

property damage.

Determine location

Locate the vent/air terminations using the following

guidelines:

1. The total length of piping for vent or air must not exceed

the limits given in the General Venting Section on page 19

of this manual.

2. You must consider the surroundings when terminating

the vent and air:

a. Position the vent termination where vapors will

not damage nearby shrubs, plants or air

conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the

plume could obstruct window views.

c. Prevailing winds could cause freezing of

condensate and water/ice buildup where flue

products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

e. Do not locate the terminations where wind eddies

could affect performance or cause recirculation,

such as inside building corners, near adjacent

buildings or surfaces, window wells, stairwells,

alcoves, courtyards, or other recessed areas.

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

TERMINATION

PLATE

BIRD SCREEN

GRADE OR

SNOW LINE

12”

MIN

BIRD SCREEN

12” MIN

15” MAX

Do not exceed the maximum lengths of the

outside vent piping shown in FIG. 4-1B.

Excessive length exposed to the outside

could cause freezing of condensate in the

vent pipe, resulting in potential boiler

shutdown.

Figure 4-1B Alternate PVC/CPVC Sidewall Termination

of Air and Vent w/Field Supplied Fittings

WARNING

If using the alternate sidewall termination:

3. The air piping must terminate in a down-turned elbow as

shown in FIG. 4-1B. This arrangement avoids recirculation

of flue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed

outward or away from the air inlet, as shown in FIG. 4-1B.

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

12"

MIN

OVER-

HANG

POSSIBLE ORIENTATIONS

Figure 4-1A PVC/CPVC Sidewall Termination of Air and

Vent

Model Kit Number Vent Size

51 - 106 KIT30044 2 inch vent

151 - 211 KIT30045 3 inch vent

Table 4A Sidewall Vent Kit

Installation & Operation Manual

4 Sidewall direct venting

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B,

pages 21 and 22. Also maintain the following:

a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

• At least 3 feet above any forced air intake within

10 feet.

• No closer than 12 inches below or horizontally

from any door or window or any other gravity air

inlet.

b. Air inlet must terminate at least 12 inches above

grade or snow line; at least 12 inches below the vent

termination (FIG. 4-1B); and the vent pipe must not

extend more than 24 inches vertically outside the

building.

c. Do not terminate closer than 4 feet horizontally

from any electric meter, gas meter, regulator, relief

valve, or other equipment. Never terminate above or

below any of these within 4 feet horizontally.

6. Locate terminations so they are not likely to be damaged by

foreign objects, such as stones or balls, or subject to buildup

of leaves or sediment.

Vent/air termination – sidewall

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

BIRD

SCREEN

12”

MIN

12” MIN

15” MAX

COUPLING

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

BIRD SCREEN

GRADE OR

SNOW LINE

Figure 4-1C Alternate Venting Arrangement (if Space

Allows) w/Field Supplied Fittings

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

12"

MIN.

Figure 4-2A Clearance to Gravity Air Inlets

12”

MIN

BIRD

SCREEN

(TYPICAL)

12”

MIN

12”

MIN

Figure 4-2B Alternate Clearance to Gravity Air Inlets

w/Field Supplied Fittings

FORCED AIR

INLET

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

IF LESS

THAN 10’

36"

MIN.

IF LESS

THAN 10’

36”

MIN

FORCED AIR

INLET

BIRD

SCREEN

(TYPICAL)

7’ MIN ABOVE ANY

PUBLIC WALKWAY

Figure 4-3B Alternate Clearance to Forced Air Inlets

w/Field Supplied Fittings

TO BOILER

INTAKE AIR

CONNECTION

FROM

BOILER

VENT PIPE

CONNECTION

BIRD SCREEN

12" MIN

15" MAX

GRADE OR SNOW LINE

Figure 4-1D Alternate Venting Arrangement - Typical

Stainless Steel Sidewall Termination of Air and Vent

w/Field Supplied Fittings

Figure 4-3A Clearance to Forced Air Inlets

Installation & Operation Manual

4 Sidewall direct venting (continued)

Termination and fittings

1. The air termination coupling must be oriented at least

12 inches above grade or snow line as shown in FIG. 4-1A,

page 21.

2. Maintain the required dimensions of the finished

termination piping as shown in FIG. 4-1A, page 21.

3. If using the alternate sidewall termination do not extend

exposed vent pipe outside of building more than shown in

this document. Condensate could freeze and block vent

pipe.

4. PVC/CPVC terminations are designed to accommodate any

wall thickness of standard constructions per the directions

found in this manual.

Prepare wall penetrations (Alternate -

Field Supplied Option)

1. Air pipe penetration:

a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

2. Vent pipe penetration:

a. Cut a hole for the vent pipe. For either combustible

or noncombustible construction, size the vent pipe

hole with at least a 1/2 inch clearance around the vent

pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe

hole as shown in FIG. 4-4B.

3. Use a sidewall termination plate as a template for correct

location of hole centers.

4. Follow all local codes for isolation of vent pipe when

passing through floors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

VENT PIPING

GALVANIZED

THIMBLE

VENT CAP

AIR PIPING

WALL PLATE

VENT PLATE

Figure 4-4A Sidewall Termination Assembly

ELBOW

BIRD SCREEN

ELBOW

BIRD SCREEN

SIDEWALL

TERMINATION PLATE

GALVANIZED

THIMBLE

VENT PIPING

AIR PIPING

Figure 4-4B Alternate Sidewall Termination Assembly

w/Field Supplied Fittings

All vent pipes and air inlets must terminate

at the same height to avoid possibility of

severe personal injury, death, or substantial

property damage.

Multiple vent/air terminations

1. When terminating multiple Knight wall mount boilers

terminate each vent/air connection as described in this

manual (FIG. 4-5A).

2. Place wall penetrations to obtain minimum clearance of 12

inches between edge of air inlet and adjacent vent outlet, as

shown in FIG. 4-5A for U.S. installations. For Canadian

installations, provide clearances required by CSA B149.1

Installation Code.

3. The air inlet of a Knight wall mount boiler is part of a direct

vent connection. It is not classified as a forced air intake

with regard to spacing from adjacent boiler vents.

WARNING

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

VENT / AIR

TERMINATION

VENT

AIR

Figure 4-5A Multiple Vent Terminations (must also

comply with Figure 4-1A)

Prepare wall penetrations

1. Use the factory supplied wall plate as a template to locate

the vent and air intake holes and mounting holes.

Air pipe penetration:

a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

Vent pipe penetration:

a. Cut a hole for the vent pipe. For either

combustible or noncombustible construction, size

the vent pipe hole with at least a 1/2 inch clearance

around the vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe

Drill 3/16" diameter holes for inserting the plastic anchors

into the wall.

2. Install the vent and air intake piping through the wall into

the vent plate openings. Seal all gaps between the pipes and

wall. Use RTV silicone sealant to seal the air pipe. Use the

cement/primer listed in Table 3A on page 17 to seal the vent

pipe.

3. Mount and secure the vent plate to the wall using stainless

steel screws. Seal around the plate to the wall assuring no

air gaps.

4. Assemble the vent cap to the vent plate (see FIG. 4-4A).

Insert the stainless steel screws into the vent cap screw hole

openings and securely attach the vent cap to the vent plate.

5. Seal all wall cavities.

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional

concentric vent

Description and usage

Lochinvar offers optional concentric combustion air and vent

pipe termination kits (Factory Kit #CVK3003 - 3" or

#CVK3008 - 2"). Both combustion air and vent pipes must

attach to the termination kit. The termination kit must

terminate outside the structure and must be installed as shown

below in FIG. 4-6.

The required combustion vent pipe and fittings are listed in

Table 3A, on page 17 of this manual.

Figure 4-7 Kit Contents

Sidewall termination installation

1. Determine the best location for the termination kit (see

FIG. 4-6).

2. The total length of piping for vent or air must not exceed the

limits given in the General Venting Section on page 19 of

this manual.

3. You must consider the surroundings when terminating

the vent and air:

a. Position the vent termination where vapors will not

damage nearby shrubs, plants or air conditioning

equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the

plume could obstruct window views.

c. Prevailing winds could cause freezing of condensate

and water/ice buildup where flue products impinge

on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

f. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate damage

to exterior finishes.

4. Cut one (1) hole (5 inch diameter for #CVK3003

installations or 4 inch diameter for #CVK3008 installations)

into the structure to install the termination kit.

5. Partially assemble the concentric vent termination kit.

Clean and cement using the procedures found in these

instructions.

a. Cement the Y concentric fitting to the larger kit pipe

(FIG. 4-7).

b. Cement the rain cap to the smaller diameter kit pipe

(FIG. 4-7).

Figure 4-6 Concentric Sidewall Termination

Figure 4-5B Alternate Multiple Vent Terminations w/Field

Supplied Fittings (must also comply with Figure 4-1B)

Installation & Operation Manual

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent models

Figure 4-8 Concentric Vent Dimensional Drawing

Instead of cementing the smaller pipe to the

rain cap, a field-supplied stainless steel screw

may be used to secure the two (2)

components together when field disassembly

is desired for cleaning (see FIG. 4-9).

When using the alternate screw assembly

method, drill a clearance hole in the rain cap

and a pilot hole in the vent pipe for the screw

size being used. Failure to drill adequate

holes may cause cracking of PVC

components, allowing combustion products

to be recirculated. Failure to follow this

warning could result in personal injury or

death.

Do not operate the appliance with the rain

cap removed or recirculation of combustion

products may occur. Water may also collect

inside the larger combustion air pipe and

flow to the burner enclosure. Failure to

follow this warning could result in product

damage or improper operation, personal

injury, or death.

Figure 4-9 Rain Cap to Vent Pipe Alternate Assembly

6. Install the Y concentric fitting and pipe assembly through

the structure’s hole.

Do not allow insulation or other materials

to accumulate inside the pipe assembly

when installing through the hole.

7. Install the rain cap and small diameter pipe assembly into

the Y concentric fitting and large pipe assembly. Ensure

small diameter pipe is bottomed and cemented in the Y

concentric fitting.

8. Secure the assembly to the structure as shown in

FIG. 4-10 using field-supplied metal strapping or

equivalent support material.

Ensure termination location clearance

dimensions are as shown in FIG. 4-6.

If assembly needs to be extended to allow

sidewall thickness requirement, the two

(2) pipes supplied in the kit may be

replaced by using the same diameter, field-

supplied SDR-26 PVC (D2241) pipe. Do

not extend dimension D more than 60

inches (see FIG. 4-8).

NOTICE

WARNING

NOTICE

If assembly needs to be reduced,

dimension D can be as short as possible.

NOTICE

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Multiventing sidewall terminations

When two (2) or more direct vent appliances are vented near

each other, each appliance must be individually vented (see FIG.

4-11). NEVER common vent or breach vent this appliance.

When two (2) or more direct vent appliances are vented near

each other, two (2) vent terminations may be installed as shown

in FIG. 4-11. It is important that vent terminations be made as

shown to avoid recirculation of flue gases.

VENT

COMBUSTION

AIR

12"

MINIMUM

Figure 4-11 Concentric Vent and Combustion Air Termination

Figure 4-10 Concentric Vent Sidewall Attachment

DO NOT use field-supplied couplings to

extend pipes. Airflow restriction will

occur and may cause intermittent

operation.

9. Cement appliance combustion air and vent pipes to the

concentric vent termination assembly. See FIG. 4-10 for

proper pipe attachment.

10. Operate the appliance one (1) heat cycle to ensure

combustion air and vent pipes are properly connected to

the concentric vent termination connections.

CAUTION

5 Vertical direct venting

Vent/air termination – vertical

Follow instructions below when

determining vent location to avoid

possibility of severe personal injury,

death or substantial property damage.

Installation must comply with local

requirements and with the National Fuel

Gas Code, ANSI Z223.1 for U.S.

installations or CSA B149.1 for

Canadian installations.

Determine location

Locate the vent/air terminations using the following

guidelines:

1. The total length of piping for vent or air must not

exceed the limits given in the General Venting section on

page 19 of this manual.

2. The vent must terminate at least 3 feet above the

highest place in which the vent penetrates the roof and

at least 2 feet above any part of a building within

10 horizontal feet.

3. The air piping must terminate in a down-turned 180°

return pipe no further than 2 feet from the center of the

vent pipe. This placement avoids recirculation of flue

products into the combustion air stream.

4. The vent piping must terminate in an up-turned

coupling as shown in FIG. 5-1A. The top of the

coupling must be at least 1 foot above the air intake.

When the vent termination uses a rain cap as illustrated

in FIG. 5-1B maintain at least 36" (914 mm) above the

air inlet. The air inlet pipe and vent pipe can be located

in any desired position on the roof, but must always be

no further than 2 feet (.6 m) apart and with the vent

termination at least 1 foot above the air intake.

ALTERNATE INTAKE LOCATIONS:

INTAKE PIPES MAY BE LOCATED

ANYWHERE WITHIN 24” OF VENT

PIPE

BIRD SCREEN

(TYPICAL)

COUPLING

(FIELD SUPPLIED)

VENT OUTLET

12” MINIMUM

ABOVE AIR INLET

6” MINIMUM

ABOVE ROOF /

SNOW LINE

VENT

COMBUSTION

AIR

Figure 5-1A PVC/CPVC Vertical Termination of Air and

Vent

5. Locate terminations so they are not likely to be damaged by

foreign objects, such as stones or balls, or subject to buildup

of leaves or sediment.

WARNING

NOTICE

WARNING Do not connect any other appliance to

the vent pipe or multiple boilers to a

common vent pipe. Failure to comply

could result in severe personal injury,

death, or substantial property damage.

WARNING Rooftop vent and air inlet terminations

must terminate in the same pressure zone,

unless vertical vent sidewall air is set up as

shown in the General Venting - Vertical

Vent, Sidewall Air Section.

6" (152 MM) MINIMUM

ABOVE ROOF /

SNOW LINE

VENT

COM,BUSTION

AIR

ALTERNATE INTAKE LOCATIONS:

INTAKE PIPES MAY BE LOCATED

ANYWHERE WITHIN 24” (610 MM)

OF VENT PIPE

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

BIRD SCREEN

(TYPICAL)

Figure 5-1B Stainless Steel Vertical Termination of Air

and Vent

Installation & Operation Manual

5 Vertical direct venting

Vent/air termination – vertical

Prepare roof penetrations

1. Air pipe penetration:

a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

2. Vent pipe penetration:

a. Cut a hole for the vent pipe. For either combustible

or noncombustible construction, size the vent pipe

hole with at least a 1/2 inch clearance around the

vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe

hole.

3. Space the air and vent holes to provide the minimum

spacing shown in FIG. 5-1A, page 27.

4. Follow all local codes for isolation of vent pipe when

passing through floors, ceilings, and roofs.

5. Provide flashing and sealing boots sized for the vent pipe

and air pipe.

Termination and fittings

1. Prepare the vent termination coupling and the air

termination elbow (FIG. 5-1A) by inserting bird screens.

Bird screens should be obtained locally.

2. The air piping must terminate in a down-turned 180°

return bend as shown in FIG. 5-1A. Locate the air inlet

pipe no further than 2 feet from the center of the vent

pipe. This placement avoids recirculation of flue

products into the combustion air stream.

3. The vent piping must terminate in an up-turned coupling

as shown in FIG. 5-1A. The top of the coupling must be

at least 1 foot above the air intake. When the vent

termination uses a rain cap as illustrated in FIG. 5-1B

maintain at least 36" (914 mm) above the air inlet. The

air inlet pipe and vent pipe can be located in any desired

position on the roof, but must always be no further than

2 feet apart and with the vent termination at least 1 foot

above the air intake.

4. Maintain the required dimensions of the finished

termination piping as shown in FIG. 5-1A.

5. Do not extend exposed vent pipe outside of building

more than shown in this document. Condensate could

freeze and block vent pipe.

Multiple vent/air terminations

1. When terminating multiple Knight wall mount boilers,

terminate each vent/air connection as described in this

manual (FIG. 5-2).

Terminate all vent pipes at the same height

and all air pipes at the same height to

avoid possibility of severe personal injury,

death, or substantial property damage.

2. Place roof penetrations to obtain minimum clearance of

12 inches between edge of air intake elbow and adjacent

vent pipe of another boiler for U.S. installations (see

FIG. 5-2). For Canadian installations, provide clearances

required by CSA B149.1 Installation Code.

3. The air inlet of a Knight wall mount boiler is part of a

direct vent connection. It is not classified as a forced air

intake with regard to spacing from adjacent boiler vents.

Figure 5-2 Vertical Terminations with Multiple Boilers

Figure 5-3 Alternate Vertical Terminations with Multiple

Boilers

WARNING

Installation & Operation Manual

5 Vertical direct venting (continued)

Vertical termination – optional concentric vent

Description and usage

Lochinvar offers an optional concentric combustion air and

vent pipe termination kit. Both combustion air and vent

pipes must attach to the termination kit. The termination

kit must terminate outside the structure and must be

installed as shown in FIG. 5-4.

Field supplied pipe and fittings are required to complete the

installation.

The required combustion air and vent pipe fittings are

listed in Table 3A, on page 17 of this manual.

Vertical termination installation

1. See Section 5, Vertical Direct Venting - Determine

Location (where applicable).

Instead of cementing the smaller pipe to the

rain cap, a field supplied stainless steel screw

may be used to secure the two (2)

components together when field disassembly

is desired for cleaning (see FIG. 4-9, page 25).

When using the alternate screw assembly

method, drill a clearance hole in the rain cap

and a pilot hole in the vent pipe for the screw

size being used. Failure to drill adequate

holes may cause cracking of PVC

components, allowing combustion products

to be recirculated. Failure to follow this

warning could result in personal injury or

death.

2. Cut one (1) hole (5 inch diameter for #CVK3003

installations or 4 inch diameter for #CVK3008 installations)

into the structure to install the termination kit.

3. Partially assemble the concentric vent termination kit.

Clean and cement following the cleaning procedures in

these instructions.

a. Cement the Y concentric fitting to the larger

diameter kit pipe (see FIG. 4-7, page 24).

b. Cement rain cap to the smaller diameter kit pipe (see

FIG. 4-7, page 24).

Figure 5-4 Concentric Vertical Termination

NOTICE

WARNING

Figure 5-5 Do Not Install U-Bend to Rain Cap

Installation & Operation Manual

5 Vertical direct venting

Vertical termination – optional concentric vent

Figure 5-6 Concentric Vent Roof Installation

Ensure termination height is above the

roof surface or anticipated snow level (12

inches in U.S.A. or 18 inches in Canada) as

shown in FIG. 5-4, page 29.

If assembly is too short to meet height

requirement, the two (2) pipes supplied in

the kit may be replaced by using the same

diameter, field supplied SDR-26 PVC

(D2241) pipe. Do not extend dimension D

more than 60 inches (see FIG. 4-8, page 25).

CAUTION DO NOT use field-supplied couplings to

extend pipes. Airflow restriction will occur.

6. Install the rain cap and the small diameter pipe assembly

into the roof penetration assembly. Ensure the small

diameter pipe is cemented and bottomed in the Y

concentric fitting.

7. Cement the appliance combustion air and vent pipes to the

concentric vent termination assembly. See FIG. 5-6 for

proper pipe attachment.

8. Operate the appliance through one (1) heat cycle to ensure

combustion air and vent pipes are properly connected to

the concentric vent termination connections.

Multiventing vertical terminations

When two (2) or more direct vent appliances are vented near

each other, each appliance must be individually vented (see

FIG. 5-7). NEVER common vent or breach vent this appliance.

When two (2) or more direct vent appliances are vented near

each other, two (2) vent terminations may be installed as shown

in FIG. 5-7. It is important that vent terminations be made as

shown to avoid recirculation of flue gases.

12”

MINIMUM

12” (18” FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24” ABOVE ROOF.

COMBUSTION

AIR (TYPICAL)

Figure 5-7 Concentric Vent and Combustion Air Vertical

Termination

Do not operate the appliance with the rain

cap removed or recirculation of

combustion products may occur. Water

may also collect inside the larger

combustion air pipe and flow to the

burner enclosure. Failure to follow this

warning could result in product damage

or improper operation, personal injury, or

death.

4. Install the Y concentric fitting pipe assembly through the

structure’s hole and field supplied roof boot/flashing.

Do not allow insulation or other materials

to accumulate inside the pipe assembly

when installing through the hole.

5. Secure the assembly to the roof structure as shown below

in FIG. 5-6 using field supplied metal strapping or

equivalent support material.

WARNING

NOTICE

Installation & Operation Manual

5 Vertical direct venting (continued)

Alternate vertical concentric venting

This appliance may be installed with a concentric vent

arrangement where the vent pipe is routed through an

existing unused venting system; or by using the existing

unused venting system as a chase for vent and combustion air

routing.

Concentric Venting Arrangement

The venting is to be vertical through the roof. The annular

space between the O.D. of the vent pipe and the I.D. of the

existing unused venting system is utilized for the combustion

air source.

The minimum size of the existing vent system required to

achieve enough annular space for combustion air can be found

in Table 5A below.

The upper and lower termination as well as any other unsealed

joints in the existing vent system must be sealed to ensure that

all combustion air is drawn from under the vent cap as shown

in FIG.’s 5-8 and 5-9.

Approved venting materials must be used as specified in Table

3A on page 17.

Follow all vent / air termination and clearance requirements

per this section to the appropriate example. Installation must

comply with local requirements and with the National Fuel

Gas Code.

The maximum allowable equivalent vent and air intake

lengths for this venting arrangement are to be determined

from the General Venting Section.

If an existing unused venting system is converted for use with

this method of concentric venting, the installer must ensure

that the existing venting system is clean and free from

particulate contamination that will harm this appliance and

cause increased nuisance calls or maintenance. See Table 1A

on page 10 for a list of corrosive contaminants and sources.

Two example scenarios of a concentric venting arrangement

are shown for illustrative purposes in FIG.’s 5-8 and 5-9.

Model Vent / Air

Inlet Size

Minimum Existing

Vent / Chase Size

51 - 106 2" 4"

151 - 211 3" 5"

Table 5A Alternate Vertical Concentric Vent / Chase Sizes

Figure 5-8 Concentric Vent Example 1

12”

MIN.

FLUE EXHAUST

AIR INLET

W/ SCREEN

FLUE OUTLET

SEALED

CAP

EXISTING

SEAL

COMBUSTION AIR

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

Figure 5-9 Concentric Vent Example 2

FLUE EXHAUST

AIR INLET

W/ SCREEN

FLUE OUTLET

SEALED

CAP

EXISTING

SEAL

COMBUSTION AIR

*For concept illustration only. Individual installations may

vary due to job site specific equipment.

Installation & Operation Manual

Figure 5-10 Existing Vent as a Chase

FLUE EXHAUST

AIR INLET

FLUE OUTLET

EXISTING

CAP

SEAL

5 Vertical direct venting

Existing vent as a chase

Follow all existing termination and clearance requirements

and allowable pipe lengths. Use only approved venting

materials listed in the General Venting Section of this manual.

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

Installation & Operation Manual

6 Hydronic piping

System water piping methods

The Knight wall mount is designed to function in a closed

loop pressurized system not less than 12 psi. A temperature

and pressure gauge is included to monitor system pressure

and outlet temperature and should be located on the boiler

outlet.

It is important to note that the boiler has a minimal amount

of pressure drop and must be figured in when sizing the

circulators. Each boiler installation must have an air

elimination device, which will remove air from the system.

Install the boiler so the gas ignition system components are

protected from water (dripping, spraying, etc.) during

appliance operation for basic service of circulator

replacement, valves, and others.

Observe a minimum of 1 inch clearance around all

un-insulated hot water pipes when openings around the pipes

are not protected by non-combustible materials.

Low water cutoff device

On a boiler installed above radiation level, some states and

local codes require a low water cutoff device at the time of

installation.

Chilled water system

If the boiler supplies hot water to heating coils in air handler

units, flow control valves or other devices must be installed to

prevent gravity circulation of heater water in the coils during

the cooling cycle. A chilled water medium must be piped in

parallel with the heater.

Freeze protection

Freeze protection for new or existing systems must use glycol

that is specially formulated for this purpose. This includes

inhibitors, which prevent the glycol from attacking the

metallic system components. Make certain to check that the

system fluid is correct for the glycol concentration and

inhibitor level. The system should be tested at least once a

year and as recommended by the producer of the glycol

solution. Allowance should be made for the expansion of the

glycol solution in the system piping.

General piping information

Basic steps are listed below along with illustrations on the

following pages (FIG.’s 6-3 through 6-10), which will guide you

through the installation of the Knight wall mount boiler

(reference FIG.’s 6-1A and 6-1B).

1. Connect the system return marked “Inlet”.

2. Connect the system supply marked “Outlet”.

3. Install purge and balance valve or shutoff valve and drain on

system return to purge air out of each zone.

4. Install a backflow preventer on the cold feed make-up water

line.

5. Install a pressure reducing valve on the cold feed make-up

water line, (15 psi nominal). Check temperature and

pressure gauge (shipped separately), which should read a

minimum pressure of 12 psi.

6. Install a circulator as shown on the piping diagrams in this

section. Make sure the circulator is properly sized for the

system and friction loss.

7. Install an expansion tank on the system supply. Consult the

tank manufacturer’s instruction for specific information

relating to tank installation. Size the expansion tank for the

required system volume and capacity.

8. Install an air elimination device on the system supply.

9. Install a drain valve at the lowest point of the system.

Note: The boiler cannot be drained completely of water

without purging the unit with an air pressure of 15 psi.

10. This appliance is supplied with a relief valve sized in

accordance with ASME Boiler and Pressure Vessel Code,

Section IV (“Heating Boilers”). The safety relief valve is

installed at the factory located on the left-hand side of the

boiler. Pipe the discharge of the safety relief valve to prevent

injury in the event of pressure relief. Pipe the discharge to

a drain. Provide piping that is the same size as the safety

relief valve outlet. Never block the outlet of the safety relief

valve.

See the *piping illustrations included in this section, FIG.’s 6-3

through 6-10 for suggested guidelines in piping the Knight wall

mount boiler with either zone valves or circulator pumps.

*Please note that these illustrations are

meant to show system piping concept only,

the installer is responsible for all equipment

and detailing required by local codes.

Use only inhibited propylene glycol

solutions, which are specifically

formulated for hydronic systems. Ethylene

glycol is toxic and can attack gaskets and

seals used in hydronic systems.

WARNING

NOTICE

Installation & Operation Manual

6 Hydronic piping

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe

requirements listed in Table 6A. Reducing the pipe size

can restrict the flow rate through the boiler, causing

inadvertent high limit shutdowns and poor system

performance. Flow rates are based on 20 feet of piping,

4 - 90° elbows, and 2 - fully ported ball valves.

2. Boiler circulating pump:

A Grundfos UPS26-99F pump will be provided by the

factory (for standard altitude models) as the boiler

circulation pump based on 20 feet of piping, 4 - 90°

elbows, and 2 - fully ported ball valves.

Knight wall mount boilers are capable of controlling a

variable speed boiler circulator. Variable speed

circulators MUST be sized to meet the specified

minimum flow requirements listed in FIG. 6-2 on page 36

at full speed.

3. Domestic hot water circulating pump:

Field supplied. The pump MUST be sized to meet

the specified minimum flow requirements listed in

FIG. 6-2. Consult the indirect water heater operating

guide to determine flow characteristics for the selected

product used.

4. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure

to use full port ball valves could result in a restricted flow

rate through the boiler.

5. Check valves:

Field supplied. Check valves are recommended for

installation as shown in FIG.’s 6-3 through 6-10. Failure

to install check valves could result in a reverse flow

condition during pump(s) off cycle.

6. Domestic indirect hot water isolation valves:

Field supplied. Full port ball valves are

required. Failure to use full port ball valves could

result in a restricted flow rate through the boiler.

7. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is

recommended when storing domestic hot water above

115°F.

8. Unions:

Field supplied. Recommended for unit serviceability.

9. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is

shipped loose. It is the responsibility of the contractor to

install the temperature and pressure gauge on the boiler

water outlet.

10. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to

ASME specifications.

11. Boiler purge valve:

Field supplied. The boiler purge valve is used to

remove entrapped air from the heat exchanger during

start-up.

12. System temperature sensor:

Lochinvar supplies a system temperature sensor.

The sensor is to be installed in the heating loop

downstream from the boiler hot water piping and

heating loop junction. Typically the sensor will be

located far enough downstream to sense system diluted

water temperature.

13. Indirect water heaters:

The Knight wall mount boiler may be piped to an indirect

water heater to heat domestic hot water with the space heat

transfer medium. As depicted in the piping diagrams on

page 38 thru 45, there are two options when utilizing an

indirect water heater.

A. The space heating piping will branch off to flow the

space heat transfer medium through a single wall

heat exchanger coil inside the indirect water heater.

B. The indirect water heater is connected to the system

supply piping. A pump controlled by the Knight

(wall mount) boiler’s control will regulate the flow of

water through the indirect water heater. The indirect

water heater’s temperature will be regulated by the

Knight (wall mount) boiler’s control.

The Knight wall mount boiler is pre-configured to control

the operation of the DHW pump with Domestic Hot Water

Prioritization programming. The DHW programming is

designed to control and balance the space heating

demand by switching between DHW and space heating.

Lochinvar offers the Squire which is a series of indirect

water heaters. The Squire features a stainless steel vessel

with a single wall stainless steel heat exchanger.

WARNING The National Standard Plumbing Code, the

National Plumbing Code of Canada and the

Uniform Plumbing Code limit the pressure

of the heat transfer fluid to less than the

minimum working pressure of the potable

water system up to 30 psi maximum. Also,

the heat transfer fluid must be water or other

non-toxic fluid having a toxicity of Class 1,

as listed in Clinical Toxicology of

Commercial Products, 5th Edition.

14. Y-Strainer:

Field supplied. A Y-strainer or equivalent multipurpose

strainer is recommended at the inlet of the heat exchanger

to remove system particles from older hydronic systems and

protect newer systems.

Installation & Operation Manual

Near boiler piping connections

VENT AIR

Y-ST RAI NE R

(RECOMMENDED)

DOMESTIC

HOT WATER

PUMP

CONDENSATE

DRAIN

SYSTEM

PUMP

BOILER

PUMP

FROMSY

STEMTOSYSTEM

FROM

INDIRECT

DOMESTIC

HOT WATER

TANK

TO FLOOR

DRAIN

AIR

SEPARATOR

EXPANSION TANK

SYSTEM

SENSOR

Figure 6-1A Near Boiler Piping w/Y-Strainer

VENT AIR

TO FLOOR

DRAIN AIR VENT

VALVE

AIR

SEPARATOR

SYSTEM

SENSOR

DRAIN (TYPICAL)

SYSTEM PUMP

LOW LOSS HEADER

(TYPICAL)

CONDENSATE

DRAIN

INDIRECT

DOMESTIC

HOT WATER

TANK

Y- S T R A I N E R

(RECOMMENDED)

DRAIN VALVE

BOILER

PUMP

FILL VALVE

EXPANSION TANK

TOSYSTEM

FROMSYSTEM

FROM

DOMESTIC HOT

WATER PUMP

AIR SEPARATOR

SYSTEM SENSOR

Figure 6-1B Near Boiler Piping w/Low Loss Header

6 Hydronic piping (continued)

Circulator sizing

The Knight wall mount boiler heat exchanger does have a pressure drop, which must be considered in your system design. Refer

to the graph in FIG. 6-2 for pressure drop through the Knight wall mount boiler heat exchanger.

Installation & Operation Manual

6 Hydronic piping

Figure 6-2 Pressure Drop vs. Flow - Models 50 - 210

20°F Temperature Rise Applications

Model GPM FT/HD Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

51 5.1 11 1" UPS26-99F 0011 NRF-36 E7

81 7.5 24 1" UPS26-99F 0011 NRF-36 E7

106 9.8 27 1" UPS26-99F 0013 NRF-36 E11

151 14.0 20 1" UPS26-99F 0011 NRF-36 E7

211 19.6 29 1" UPS32-160 1400-50 PL-55 E9

Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35°

25°F Temperature Rise Applications

Model GPM FT/HD Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

51 4.1 7.3 1" UPS15-58FC 0014 NRF-36 E7

81 5.9 15.0 1" UPS15-58FC 0014 NRF-36 E7

106 7.7 17.5 1" UPS26-99F 0014 NRF-36 E7

151 11.0 12.8 1" UPS26-99F 0014 NRF-36 E7

211 15.5 19.0 1" UPS26-99F 0013 NRF-36 E7

35°F Temperature Rise Applications

Model GPM FT/HD Minimum Pipe

Size

Pump

Grundfos TACO B & G Armstrong

51 2.9 4.1 1" UPS15-58FC 007 NRF-22 Astro-30

81 4.2 7.3 1" UPS15-58FC 007 NRF-22 Astro-30

106 5.5 9.8 1" UPS15-58FC 007 NRF-22 Astro-30

151 7.9 10 1" UPS15-58FC 008/0010 NRF-36 Astro-30

211 11.0 10.1 1" UPS15-58FC 0010 NRF-36 Astro-50

Pumps listed in bold type are provided by the factory as the boiler circulation pump on standard altitude

models.

NOTICE

Pumps listed in italicized type are provided by the factory as the boiler circulation pump on high altitude

models.

NOTICE

The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.

NOTICE

6 Hydronic piping (continued)

It is required that near boiler piping systems

utilize Primary/Secondary configurations as

shown in FIG.’s 6-3 through 6-10 only. The

use of other near boiler piping configurations

could result in improper building and system

flow rates leading to inadvertent boiler high

limit shutdowns and poor system

performance.

NOTICE

Pump sizing and flow requirements are

based on 20 feet of piping, 4 - 90° elbows,

and 2 - fully ported ball valves.

NOTICE

Variable speed pump option

Table 6B Recommended Variable Speed Pumps

*The minimum temperature rise is derived from the chart in FIG. 6-2 with the firing rate and pump speed at 100% as shown in

the table above.

The shaded regions of pump coverage are only available for applications with 230V (60 Hz) supply voltage, all others are

to be 115V. (A field supplied relay is required to connect the 230V pump listed in the shaded area in Table 6B to the boiler

high voltage terminal strip.)

Variable speed pump setup

Before operation, ensure the following:

- Pump is set for an input signal of 0 - 10Vdc by the dip switches on the pump control

- Pump is set for external signal control (if applicable)

- Pump is set for linear output (if applicable)

- If pump does not come equipped with a 0 - 10 Vdc input option, an optional module

will be required from the vendor

Installation & Operation Manual

Minimum Temperature Rise*

Model

Pump

Grundfos

UP26-96 FC/VS

TACO

0013 IFC VS

Wilo

Stratos 1.25 3 x 30

51/81 20.3 20.3 21.7

106 22.3 21.0 21.5

151 21.2 19.8 19.1

211 26.8 25.1 23.6

Installation & Operation Manual

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

DRAIN

DRAIN POINT

(TYPICAL)

MAKE UP WATER

HOT

WATER

OUT

ZONE CIRCULATORS

(TYPICAL)

FLOW CHECK

VALVE

(TYPICAL)

BOILER

CIRCULATOR

SYSTEM SUPPLY

SENSOR

PRESSURE

RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

MAY SUBSTITUTE LOW LOSS HEADER

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-3 Single Boiler - Single Temperature Zoned with Circulators

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

6 Hydronic piping

Installation & Operation Manual

INDIRECT

DHW TANK

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

AIR SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE UP

WATER

ZONE CIRCULATORS

(TYPICAL)

FLOW CHECK

VALVE

(TYPICAL)

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

BOILER

CIRCULATOR

BOILER 2

(MEMBER 1)

DOMESTIC

HOT WATER

CIRCULATOR

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

HOT

WATER

OUT

COLD

WATER

BOILER 1

(LEADER)

SYSTEM SUPPLY

SENSOR

TEMPERATURE /

PRESSURE

GAUGE

DRAIN

Y-STRAINER

(RECOMMENDED)

(TYPICAL)

MAY SUBSTITUTE LOW LOSS HEADER

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-4 Multiple Boilers - Single Temperature Zoned with Circulators

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

51 1" 1-1/4" 1-1/2" 2" 2" 2" 2"

81 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2"

106 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"

151 2" 2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2"

211 2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 4"

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

6 Hydronic piping (continued)

Installation & Operation Manual

6 Hydronic piping

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE

WATER

HOT

WATER

OUT

BOILER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

EXPANSION

TANK

MIXING VALVES

(TYPICAL)

FLOW CHECK

VALVE

SYSTEM

SUPPLY

SENSOR

DRAIN

Y-STRAINER

(RECOMMENDED)

MAY SUBSTITUTE

LOW LOSS HEADER

TEMPERATURE

LOOP #1

TEMPERATURE

LOOP #2

TEMPERATURE

LOOP #3

NOT TO EXCEED 4 PIPE DIA

OR MAX. OF 12" APART

Figure 6-5 Single Boiler - Multiple Temperatures

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

CAUTION Mixing valves are required for the protection of low temperature loops.

6 Hydronic piping (continued)

DOMESTIC

HOT WATER

CIRCULATOR

ANTI-SCALD

MIXING VALVE

COLD

WATER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE

WATER

HOT

WATER

OUT

BOILER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

EXPANSION

TANK

MIXING VALVES

(TYPICAL)

FLOW CHECK

VALVE

SYSTEM

SUPPLY

SENSOR

MAY SUBSTITUTE

LOW LOSS HEADER

TEMPERATURE

LOOP #1

TEMPERATURE

LOOP #2

TEMPERATURE

LOOP #3

BOILER

INDIRECT

DHW TANK

TEMPERATURE /

PRESSURE

GAUGE

UNION

(TYPICAL)

DRAIN

Y-STRAINER

(RECOMMENDED)

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

BOILER

Figure 6-6 Multiple Boilers - Multiple Temperatures

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

51 1" 1-1/4" 1-1/2" 2" 2" 2" 2"

81 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2"

106 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"

151 2" 2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2"

211 2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 4"

Installation & Operation Manual

CAUTION Mixing valves are required for the protection of low temperature loops.

6 Hydronic piping

Figure 6-7 Multiple Boilers - Multiple Temperatures with DHW Piped as a Zone

DOMESTIC

HOT WATER

CIRCULATOR

ANTI-SCALD

MIXING VALVE

COLD

WATER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE

WATER

HOT

WATER

OUT

BOILER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

EXPANSION

TANK

MIXING VALVES

(TYPICAL)

FLOW CHECK

VALVE

SYSTEM

SUPPLY

SENSOR

MAY SUBSTITUTE

LOW LOSS HEADER

TEMPERATURE

LOOP #1

TEMPERATURE

LOOP #2

TEMPERATURE

LOOP #3

BOILER

INDIRECT

DHW TANK

UNION

(TYPICAL)

DRAIN

Y-STRAINER

(RECOMMENDED)

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

BOILER

TEMPERATURE /

PRESSURE GAUGE

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

51 1" 1-1/4" 1-1/2" 2" 2" 2" 2"

81 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2"

106 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"

151 2" 2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2"

211 2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 4"

Installation & Operation Manual

Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

NOTICE

CAUTION Mixing valves are required for the protection of low temperature loops.

Installation & Operation Manual

6 Hydronic piping (continued)

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

DRAIN POINT

(TYPICAL)

MAKE UP WATER

HOT

WATER

OUT

BOILER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE PRESSURE

GAUGE

EXPANSION

TANK

ZONE VALVES

(TYPICAL)

FLOW CHECK

VALVE

DIFFERENTIAL

PRESSURE BYPASS

VALVE (IF USED)

SYSTEM

CIRCULATOR

SYSTEM SUPPLY

SENSOR

DRAIN

Y-STRAINER

(RECOMMENDED)

MAY SUBSTITUTE LOW LOSS HEADER

ZONE #1

ZONE #2 ZONE #3 ZONE #4

Figure 6-8 Single Boiler Zoned with Valves

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

Installation & Operation Manual

6 Hydronic piping

INDIRECT

DHW TANK

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

MAKE UP WATER

ZONE VALVES

(TYPICAL)

BOILER

CIRCULATOR

BOILER 2

(MEMBER 1)

DOMESTIC

HOT WATER

CIRCULATOR

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

HOT

WATER

OUT

COLD

WATER

BOILER 1

(LEADER)

DIFFERENTIAL

PRESSURE BYPASS

VALVE (IF USED)

SYSTEM SUPPLY

SENSOR

SYSTEM

CIRCULATOR

DRAIN

Y-STRAI N E R

(RECOMMENDED)

(TYPICAL)

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

MAY SUBSTITUTE LOW LOSS HEADER

ZONE #1

ZONE #2 ZONE #3 ZONE #4

FLOW CHECK

VALVE

Figure 6-9 Multiple Boilers Zoned with Valves

Model

Number of Units

2 3 4 5 6 7 8

Required Pipe Sizes

51 1" 1-1/4" 1-1/2" 2" 2" 2" 2"

81 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2"

106 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"

151 2" 2" 2-1/2" 2-1/2" 3" 3-1/2" 3-1/2"

211 2" 2-1/2" 3" 3-1/2" 3-1/2" 4" 4"

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

Installation & Operation Manual

BOILER

INDIRECT

DHW TANK

DOMESTIC

HOT WATER

CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

ANTI-SCALD

MIXING VALVE

COLD

WATER

TEMPERATURE /

PRESSURE

GAUGE

AIR

SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

DRAIN POINT

(TYPICAL)

MAKE UP WATER

FROM

SYSTEM

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

BOILER

CIRCULATOR

SYSTEM

CIRCULATOR

SYSTEM

SYSTEM SUPPLY

SENSOR

DRAIN

MAY SUBSTITUTE LOW LOSS HEADER

Y-STRAINER

(RECOMMENDED)

HOT

WATER

OUT

FLOW CHECK VALVE

Figure 6-10 Single Boiler - Non-Zoned Primary/Secondary Piping

6 Hydronic piping (continued)

Please note that these illustrations are meant to show system piping concept only, the installer is responsible

for all equipment and detailing required by local codes.

NOTICE

7 Gas connections

Connecting gas supply piping

1. Remove the front access panel and refer to FIG. 7-1 to

pipe gas to the boiler.

a. Install a field supplied sediment trap / drip leg

upstream of the boiler gas controls.

MANUAL SHUTOFF VALVE

(FIELD SUPPLIED)

UNION

DRIP LEG

GAS SUPPLY

Figure 7-1 Gas Supply Piping

2. Support piping with hangers, not by the boiler or its

accessories.

Do not check for gas leaks with an open

flame – use the bubble test. Failure to use

the bubble test or check for gas leaks can

cause severe personal injury, death, or

substantial property damage.

3. Purge all air from the gas supply piping.

4. Before placing the boiler in operation, check the boiler and

its gas connection for leaks.

a. Close manual main shutoff valve during any

pressure testing at less than 13 inches w.c.

b. Disconnect the boiler and gas valve from the gas

supply piping during any pressure testing greater

than 13 inches w.c.

The gas valve and blower will not support

the weight of the piping. Do not attempt to

support the weight of the piping with the

boiler or its accessories. Failure to comply

could result in severe personal injury, death,

or substantial property damage.

WARNING

5. Use pipe sealing compound compatible with propane gases.

Apply sparingly only to male threads of the pipe joints so

that pipe dope does not block gas flow.

Installation & Operation Manual

7 Gas connections (continued)

Failure to apply pipe sealing compound

as detailed in this manual can result in

severe personal injury, death, or

substantial property damage.

Knight wall mount boilers are typically

shipped ready to fire on natural gas.

Check boiler rating plate to determine

which fuel the boiler is set for. If set to

natural gas, it may be converted to LP by

installing an orifice (see page 13). In

order to operate on LP gas, an orifice

MUST BE installed. Failure to comply

could result in severe personal injury,

death, or substantial property damage.

Use two wrenches when tightening gas

piping at boiler (FIG. 7-2), using one

wrench to prevent the boiler gas line

connection from turning. Failure to

support the boiler gas connection pipe to

prevent it from turning could damage gas

line components.

USE BACKUP WRENCH

TO PREVENT PIPE FROM

ROTATING

Figure 7-2 Inlet Pipe with Backup Wrench

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 7A for pipe length and diameter. Based on

rated boiler input (divide by 1,000 to obtain cubic feet per

hour).

a. Table 7A is only for natural gas with specific gravity

0.60 inches, with a pressure drop through the gas

piping of 0.5 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with

boiler on.

• Minimum 4 inches w.c. with gas flowing (verify during

boiler startup).

2. Install 100% lockup gas pressure regulator in supply line if

inlet pressure can exceed 14 inches w.c. at any time. Adjust

lockup regulator for 14 inches w.c. maximum.

Propane Gas:

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100%

lockup gas pressure regulator.

Propane Supply Pressure Requirements

1. Adjust propane supply regulator provided by the gas

supplier for 14 inches w.c. maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with

boiler on.

• Minimum 8 inches w.c. with gas flowing (verify during

boiler startup).

Maximum inlet gas pressure must not

exceed the value specified. Minimum

value listed is for the purposes of input

adjustment.

WARNING

WARNING Knight wall mount boilers are typically

shipped ready to fire on natural gas. Check

boiler rating plate to determine which fuel

the boiler is set for. If set to natural gas, it

may be converted to LP by installing an

orifice (see page 13). In order to operate on

LP gas, an orifice MUST BE installed. Failure

to comply could result in severe personal

injury, death, or substantial property damage.

NOTICE

WARNING Ensure that the high gas pressure regulator

is at least 6 - 10 feet upstream of the

appliance.

Installation & Operation Manual

7 Gas connections

Nominal

Iron Pipe

Size (Inches)

Natural Gas Pipe Capacity Chart

Length of Pipe in Straight Feet for 1/2 PSI

100

125

150

175

200

1/2

175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

3/4

369

256

205

174

155

141

128

121

113

106

697

477

384

328

292

267

246

236

210

200

179

164

149

138

1-1/4

1400

974

789

677

595

543

502

472

441

410

369

333

308

287

1-1/2

2150

1500

1210

1020

923

830

769

707

666

636

564

513

472

441

4100

2820

2260

1950

1720

1560

1440

1330

1250

1180

1100

974

871

820

2-1/2

6460

4460

3610

3100

2720

2460

2310

2100

2000

1900

1700

1540

1400

1300

11200

7900

6400

5400

4870

4410

4000

3800

3540

3330

3000

2720

2500

2340

23500

16100

13100

11100

10000

9000

8300

7690

7380

6870

6150

5640

5130

4720

Knight wall mount boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to

determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifice

(see page 13). In order to operate on LP gas, an orifice MUST BE installed. Failure to comply could result in

severe personal injury, death, or substantial property damage.

Table 7A Natural Gas Pipe Size Chart

The gas piping must be sized for the proper flow and length

of pipe, to avoid excessive pressure drop. Both the gas meter

and the gas regulator must be properly sized for the total gas

load.

If you experience a pressure drop greater than 1 inch w.c.,

the meter, regulator, or gas line is undersized or in need of

service. Perform the steps below when checking inlet gas

supply:

1. Turn the main power switch to the “OFF” position.

2. Shut off gas supply at the manual gas valve in the gas

piping to the appliance.

WARNING

3. Loosen the set screw one (1) full turn from inside the

pressure tap on top of the gas valve. Place the tubing of

the manometer over the tap once the set screw is

loosened as shown in FIG. 7-3.

4. Slowly turn on the gas supply at the field installed

manual gas valve.

5. Turn the power switch to the “ON” position.

6. Adjust the temperature set point on the control panel of

the SMART SYSTEM control module to call for heat.

7. Observe the gas supply pressure as the burner fires at

100% of rated input. Percent of burner input will be

displayed on the control panel.

8. Ensure inlet pressure is within specified range.

Minimum and maximum gas supply pressures are

specified in this section of the manual.

9. If gas supply pressure is within normal range and no

adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility,

gas supplier, qualified installer or service agency to

determine the necessary steps to provide proper gas

pressure to the control.

11. Turn the power switch to the “OFF” position.

12. Shut off the gas supply at the manual gas valve in the gas

piping to the appliance.

13. Remove the manometer from the pressure tap on top of

the gas valve. Re-tighten the set screw inside the pressure

tap.

Check inlet gas supply

NOTICE CSA or UL listed flexible gas

connections are acceptable, but you

must exercise caution to ensure that the

line has adequate capacity to allow your

boiler to fire at full rate. Consult with

local codes for proper installation or

service procedures.

DO NOT adjust or attempt to measure

gas valve outlet pressure. The gas valve is

factory-set for the correct outlet

pressure. This setting is suitable for

natural gas and propane, requiring no

field adjustment. Attempting to alter or

measure the gas valve outlet pressure

could result in damage to the valve,

causing potential severe personal injury,

death, or substantial property damage.

WARNING

Installation & Operation Manual

7 Gas connections (continued)

WARNING When re-tightening the set screw, be

sure to tighten securely to prevent gas

leaks.

Do not check for gas leaks with an open

flame -- use the bubble test. Failure to

use the bubble test or check for gas leaks

can cause severe personal injury, death,

or substantial property damage.

14. Turn on the gas supply at the manual gas valve.

15. Turn the power switch to the “ON” position.

16. Adjust the temperature set point on the control panel

of the SMART SYSTEM control module to the desired

water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while

you observe burner response. The burner should

ignite promptly. Flame pattern should be stable. Turn

system off and allow burner to cool, then cycle burner

again to ensure proper ignition and flame

characteristics.

Gas Pressure

The gas pressure must remain between 4 inches w.c. (natural),

8 inches w.c. (LP) minimum and 14 inches w.c. (natural and LP)

maximum during stand-by (static) mode and while in operating

(dynamic) mode. If an in-line regulator is used, it must be a

minimum of 10 feet from the Knight wall mount boiler. It is

very important that the gas line is properly purged by the gas

supplier or utility company. Failure to properly purge the lines

or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations

and also in empty tank situations. This can also occur when a

utility company shuts off service to an area to provide

maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas

valve under any circumstances. As an additional safety feature,

this gas valve has a flanged connection to the venturi and blower.

DETAIL

LOOSEN SET SCREW ONE (1)

FULL TURN THEN PLACE

TUBING OVER PRESSURE TAP

Figure 7-3 Inlet Gas Supply Check

DO NOT adjust or attempt to measure gas

valve outlet pressure. The gas valve is

factory-set for the correct outlet pressure.

This setting is suitable for natural gas and

propane, requiring no field adjustment.

Attempting to alter or measure the gas

valve outlet pressure could result in

damage to the valve, causing potential

severe personal injury, death, or

substantial property damage.

Failure to follow all precautions could

result in fire, explosion, or death!

WARNING

8 Field wiring

ELECTRICAL SHOCK HAZARD – For

your safety, turn off electrical power

supply before making any electrical

connections to avoid possible electric

shock hazard. Failure to do so can cause

severe personal injury or death.

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler

must be replaced, use only type 105°C

wire or equivalent.

Boiler must be electrically grounded as

required by National Electrical Code

ANSI/NFPA 70 – latest edition.

Installation must comply with:

1. National Electrical Code and any other national, state,

provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1,

and any local codes.

3. Wire the boiler pump as shown in FIG. 8-2.

4. When connecting a domestic hot water (DHW) pump,

connect the wiring to the line voltage terminal strip as

shown in FIG. 8-2.

5. To activate a system pump, wire as shown in FIG. 8-2. If the

motor is larger than 1/8 hp or 1.8 amps, you must isolate

with a relay.

Figure 8-2 Line Voltage Field Wiring Connections

Label all wires prior to disconnection

when servicing controls. Wiring errors

can cause improper and dangerous

operation.

WARNING

NOTICE

CAUTION

REMOVE BEZE

Figure 8-1 Remove Bezel

Low voltage connections

1. Route all low voltage wires through the knockouts in the

bottom front right side, just under the control panel, as

shown in FIG. 8-3.

2. Connect low voltage wiring to low voltage connection board

as shown in FIG. 8-4 on page 53 of this manual and the

boiler wiring diagram.

LOW VOLTAGE

WIRING KNOCKOUTS

LOW VOLTAGE

CONNECTION BOARD

LINE VOLTAGE

WIRING KNOCKOUTS

LINE VOLTAGE

JUNCTION BOX

Figure 8-3 Routing Field Wiring

Line voltage connections

1. Remove bezel as shown in FIG. 8-1.

2. Connect 120 vac power wiring to the line voltage terminal

strip in the junction box, as shown in FIG. 8-2.

2. Provide and install a fused disconnect or service switch

(15 amp recommended) as required by the code (see

FIG. 8-2).

Installation & Operation Manual

8 Field wiring (continued)

Thermostat

1. Connect the room thermostat or end switch (isolated

contact only) to room thermostat 1, 2, or 3, as shown in

FIG. 8-4.

2. Install the thermostat on the inside wall away from

influences of drafts, hot or cold water pipes, lighting

fixtures, television, sunlight, or fireplaces.

3. Thermostat anticipator (if applicable):

a. If connected directly to boiler, set for 0.1 amps.

b. If connected to relays or other devices, set to

match total electrical power requirements of

connected devices. See device manufacturers’

specifications and thermostat instructions for

details.

Outdoor temperature sensor

1. Mount the sensor on an exterior wall, shielded from

direct sunlight or flow of heat or cooling from other

sources.

2. Route sensor wires through a knockout in the bottom

front right side of the boiler (see FIG. 8-3).

3. Connect outdoor temperature sensor (FIG. 8-4) to the

outdoor sensor terminals on the connection board to

enable outdoor reset operation of the Knight wall mount

boiler. If fixed temperature operation is required, do not

install outdoor sensor.

DHW thermostat

1. Connect storage indirect water heater (DHW)

thermostat (FIG. 8-4) to the DHW thermostat terminals

on the connection board. If a tank sensor is connected

(see DHW Tank Sensor below) the tank thermostat is

ignored.

Louver relay

1. If louvers need to operate when the boiler fires, they can be

controlled by this output. Connect these terminals to a 24

vac relay coil, which is wired to operate the louvers

(FIG. 8-4).

Louver proving switch

1. When the operation of the louvers needs to be verified

before the boiler fires, remove the jumper wire from these

terminals and connect them to the normally open contacts

on its proving switch (FIG. 8-4).

Flow switch

1. A flow switch is used to guarantee flow through the boiler

before allowing it to fire. The flow switch must be installed

at the boiler outlet.

2. Connect these terminals to the normally open contacts on

the flow switch (FIG. 8-4).

DHW tank sensor

1. By installing a tank sensor, the SMART SYSTEM control

can perform the tank thermostat function. The SMART

SYSTEM control automatically detects the presence of

this sensor and generates a DHW call for heat when the

tank temperature drops 6°F (3°C) below the tank set

point and finishes the call for heat when the tank

temperature reaches the tank set point.

2. The tank sensor included with the Lochinvar Squire

Indirect DHW tank (TST20015) is the only sensor

suitable for use with the SMART SYSTEM control.

Connect the sensor leads to the Tank Sensor terminals on

the Low Voltage Connection Board. Consult the tank

manufacturer for application and performance when

used with any other indirect tank.

Failure to use the correct sensor may

result in the tank temperature being either

above or below the set point. Failure to

consult the manufacturer of the indirect

tank, when the Squire is not used, may

result in decreased performance or the

risk of scald injury.

WARNING

3. If the TST20015 is not compatible with the indirect tank, a

tank thermostat can be used to control the boiler. The tank

thermostat should be installed per the manufacturers

instructions and wired to the DHW Thermostat terminals

on the Low Voltage Connection Board.

Variable speed system pump

If a variable speed pump is used in the primary loop, and a

0-10V signal is available from the pump speed control, this

signal can be used by the SMART SYSTEM control to anticipate

changes in the building heat load. By connecting this 0 - 10V

signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or

cascade) can modulate up and down as the primary flow

increases and decreases.

Boiler pump speed output

This 0 - 10V output is available to control the speed of a variable

speed boiler pump. The SMART SYSTEM control will vary the

speed of this pump in order to maintain a minimum ΔT across

the heat exchanger, as well as prevent high limit lockouts when

the flow in the primary loop is extremely low. Connect this

output to the 0 - 10V input on the boiler pump speed control.

Rate output

This output provides a 0 - 10V signal that is proportional to the

firing rate of the boiler. This may be used by a BMS system to

monitor the actual rate of the boiler.

Modbus

When the optional ModBus interface module is installed, the

RS-485 ModBus cable is connected to these terminals. Use

shielded, 2-wire twisted pair cable. If desired, the shield can be

connected to ground by installing a jumper wire between

terminals 1 and 3 on connector X5 on the optional ModBus

interface module.

Installation & Operation Manual

8 Field wiring

Boiler management system

1. An external control may be connected to control either

the firing rate or the set point of the boiler. If the external

control uses a set of contacts to enable the boiler, connect

the contacts to the Room Thermostat 1 terminals.

Otherwise, the SMART SYSTEM control will be enabled

by the 0-10V signal.

2. Make sure the ground terminal is connected to the

ground output terminal of the external control, and the

0 - 10 vdc terminal is connected to the 0 - 10 vdc terminal

of the external control.

Runtime contacts

The SMART SYSTEM control closes a set of dry contacts

whenever the burner is running. This is typically used by

Building Management Systems to verify that the boiler is

responding to a call for heat.

Alarm contacts

The SMART SYSTEM control closes another set of contacts

whenever the boiler is locked out or the power is turned off.

This can be used to turn on an alarm, or signal a Building

Management System that the boiler is down.

Wiring of the cascade

When wiring the boilers for Cascade operation, select one boiler

as the Leader boiler. The remaining boilers will be designated as

Members. See page 60 “Configuration of the Cascade” for a

detailed explanation of this procedure.

Connect the system supply sensor and outdoor air sensor (if

used) to the Leader boiler. For the Cascade system to work

properly the system supply sensor must be installed. The

location of the system supply sensor should be downstream of

the boiler connections in the main system loop (FIG.’s 6-4 and

6-6). The system supply sensor should be wired to the Low

Voltage Connection Board at the terminals marked for the

system sensor (see FIG. 8-4). The Leader control will use the

water temperature at the system supply sensor to control the

operation of the Cascade.

If outdoor air reset is desired, the outdoor air sensor should be

wired to the Low Voltage Connection Board at the terminals

marked for the outdoor air sensor (FIG. 8-4). If the outdoor air

sensor is connected, the Leader control will calculate the water

temperature set point based on the programmed reset curve

parameters. If the outdoor air sensor is not connected, the

Leader control will maintain the fixed water temperature set

point that is programmed into the control.

If a Thermostat, Zone Control enable output, or Building

Management System enable output is available, it should be

wired to the Low Voltage Connection Board on the Leader boiler

at the terminals marked for one of the Room Thermostats 1-3

(FIG. 8-4). If the boilers are to run continuously, connect a

jumper wire between the R and W terminals for the Thermostat

input. This will initiate a call for heat on the Cascade.

Communication between the Leader boiler and the Member

boilers is accomplished by using shielded, 2-wire twisted pair

communication cable. Connect one of the twisted pair wires to

Cascade terminal A on each of the Low Voltage Connection

boards, and the other wire of the twisted pair to Cascade

terminal B on each of the Low Voltage Connection Boards.

Connect the shield wires to one of the shield terminals on the

Low Voltage Connection Boards (FIG. 8-4). If more than two

boilers are on the Cascade, daisy chain the wiring from the

Cascade terminals on the second boiler to the Cascade terminals

on the third boiler, then from the third to the forth, and so on.

The connections between boilers can be made in any order,

regardless of the addresses of the boilers. Try to keep each cable

as short as possible.

System supply sensor

1. By installing the system supply sensor into the supply of

the primary loop, the temperature of the primary supply

can be controlled. The SMART SYSTEM control

automatically detects the presence of this sensor, and

controls the boiler firing rate to maintain the system

supply temperature to the set point (if the outlet sensor

control is currently selected). If it is desired to control the

system return temperature, then program the SMART

SYSTEM control to use the inlet sensor as the controlling

sensor. See the Knight Wall Mount Service Manual for

instructions on how to do this. When the inlet sensor is

programmed as the controlling sensor, it is strongly

recommended that the SYSTEM SUPPLY sensor be

installed. DO NOT INSTALL THE SYSTEM SUPPLY

SENSOR INTO THE SYSTEM RETURN.

2. The TST2032 sensor provided with the boiler must be

used for the system sensor.

3. Connect these terminals to the system supply sensor

(FIG. 8-4).

Installation & Operation Manual

8 Field wiring (continued)

LOUVER RELAY

FLOW SWITCH

TANK THERMOSTAT

ROOM THERMOSTAT 3

SYSTEM SUPPLY SENSOR

BUILDING

MANAGEMENT

SYSTEM

LOUVER

PROVING SWITCH

COM

LOW WATER

CUTOFF

OUTDOOR SENSOR

TANK SENSOR

SHIELD SHIELD

BOILER

ROOM THERMOSTAT 1

ROOM THERMOSTAT 2

NOTE:

CONNECTION BOARD SPLIT FOR

ILLUSTRATION PURPOSES

WIRE AS

NEEDED

SYSTEM PUMP

SPEED CONTROL

BOILER PUMP

A B

Figure 8-4 Low Voltage Field Wiring Connections

Installation & Operation Manual

9 Condensate disposal

Condensate drain

1. This boiler is a high efficiency appliance that produces

condensate.

2. The bottom of the boiler has a 1/2 inch pipe for

connection of a 1/2 inch PVC pipe (FIG. 9-1).

3. Slope condensate tubing down and away from the boiler

into a drain or condensate neutralizing filter. Condensate

from the Knight wall mount boiler will be slightly acidic

(typically with a pH from 3 to 5). Install a neutralizing

filter if required by local codes.

A Neutralizer Kit is available from the factory (Kit 3087).

4. Do not expose condensate line to freezing temperatures.

5. Use only plastic tubing or piping as a condensate drain

line (FIG. 9-1).

6. Leave the top of the tee assembly installed in the unit

open, this is needed as a vacuum break. The blocked drain

switch will shut the boiler down before any condensate

can flow out of the tee.

Use materials approved by the authority

having jurisdiction. In the absence of other

authority, PVC and CPVC pipe must comply

with ASTM D1785 or D2845. Cement and

primer must comply with ASME D2564 or

F493. For Canada use CSA or ULC certified

PVC or CPVC pipe, fittings, and cement.

7. A condensate removal pump is required if the boiler is

below the drain. When installing a condensate pump, select

one approved for use with condensing boilers and furnaces.

The pump should have an overflow switch to prevent

property damage from condensate spillage. The switch

should be wired in series with the blocked drain switch

inside the boiler (see FIG. 10-1 on page 56).

NOTICE

NOTICE To allow for proper drainage on large

horizontal runs, a second line vent may be

required and tubing size may need to increase

to 1 inch.

The condensate line must remain

unobstructed, allowing free flow of

condensate. If condensate is allowed to freeze

in the line or if the line is obstructed in any

other manner, condensate can exit from the

boiler tee, resulting in potential water damage

to property.

CONDENSATE TRAP

REMOVABLE CAP

FOR CLEANING TRAP

CONDENSATE DRAIN CONNECTION -

ROUTE TO FLOOR DRAIN OR

NEUTRALIZING FILTER USING:

1/2" PVC PIPE & FITTINGS or

1/2" CPVC PIPE & FITTINGS or

5/8" I.D. PLASTIC TUBING

(FIELD SUPPLIED)

Figure 9-1 Condensate Disposal

10 Start-up

Check/control water chemistry

Do not use petroleum-based cleaning or

sealing compounds in the boiler system.

Damage to elastomer seals and gaskets in

the system could occur, resulting in

substantial property damage.

Hardness less than 7 grains

1. Consult local water treatment companies for hard water

areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1. Do not fill boiler or operate with water containing

chlorine in excess of 200 ppm.

2. Filling with chlorinated fresh water should be acceptable

since drinking water chlorine levels are much lower.

3. Do not use the boiler to directly heat swimming pool or

spa water.

Test/replace freeze protection fluid

1. For systems using freeze protection fluids, follow fluid

manufacturer’s instructions.

2. Freeze protection fluid must be replaced periodically due

to degradation of inhibitors over time. Follow all fluid

manufacturer’s instructions.

Freeze protection (when used)

1. Determine freeze protection fluid quantity using system

water content, following fluid manufacturer’s

instructions. Boiler water content is listed on page 6.

Remember to include expansion tank water content.

2. Local codes may require a backflow preventer or actual

disconnect from city water supply.

3. When using freeze protection fluid with automatic fill,

install a water meter to monitor water makeup. Freeze

protection fluid may leak before the water begins to leak,

causing concentration to drop, reducing the freeze

protection level.

4. The freeze protection set points may be lowered when

freeze protection fluid is used (see the Knight Wall

Mount Service Manual).

Fill and test water system

1. Fill system only after ensuring the water meets the

requirements of this manual.

2. Close manual and automatic air vents and boiler drain

valve.

3. Fill to correct system pressure. Correct pressure will vary

with each application.

a. The minimum cold water fill pressure for a

residential system is 12 psi.

b. Pressure will rise when boiler is turned on and

system water temperature increases.

Eliminate all system leaks. Continual fresh

makeup water will reduce boiler life.

Minerals can build up in the heat exchanger,

reducing heat transfer, overheating the heat

exchanger, and causing heat exchanger

failure.

Purge air from water system

1. Purge air from system:

a. Connect a hose to the purge valve (see purge/drain

valves, in piping diagrams on pages 38 through 45).

Route the hose to an area where water can drain and

be seen.

b. Close the boiler or system isolation valve between

the purge valve and fill connection to the system.

c. Close zone isolation valves.

d. Open quick-fill valve on cold water makeup line.

e. Open purge valve.

f. One zone at a time, open the isolation valves. Allow

water to run through the zone, pushing out the air.

Run until no noticeable air flow is present. Close the

zone isolation valves and proceed with the next zone.

Follow this procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve and

remove the hose. Open all isolation valves. Watch

that system pressure rises to correct cold-fill

pressure.

h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located

throughout the system.

i. If purge valves are not installed in the system, open

the manual air vents in the system one at a time,

beginning with the lowest floor. Close the vent when

water squirts out. Repeat with remaining vents.

2. Open automatic air vent (diaphragm-type or bladder-type

expansion tank systems only) one turn.

3. Open other vents:

a. Starting on the lowest floor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

4. Refill to correct pressure.

4. At initial fill and during boiler startup and testing, check

system thoroughly for any leaks. Repair all leaks before

proceeding further.

WARNING

CAUTION

Installation & Operation Manual

10 Start-up

Check for gas leaks

Before starting the boiler, and during

initial operation, smell near the floor and

around the boiler for gas odorant or any

unusual odor. Remove the front access

panel and smell the interior of the boiler

enclosure. Do not proceed with startup if

there is any indication of a gas leak. Use

an approved leak detection solution.

Repair any leaks at once.

DO NOT adjust or attempt to measure gas

valve outlet pressure. The gas valve is

factory set for the correct outlet pressure.

This setting is suitable for natural gas and

propane, requiring no field adjustment.

Attempting to alter or measure the gas

valve outlet pressure could result in

damage to the valve, causing potential

severe personal injury, death, or

substantial property damage.

Propane boilers only – Your propane

supplier mixes an odorant with the

propane to make its presence detectable.

In some instances, the odorant can fade,

and the gas may no longer have an odor.

Before startup (and periodically

thereafter), have the propane supplier

verify the correct odorant level in the gas.

Check thermostat circuit(s)

1. Disconnect the two external wires connected to each of the

room thermostat terminals on the connection board.

2. Connect a voltmeter across these two incoming wires. Close

each thermostat, zone valve, and relay in the external circuit

one at a time and check the voltmeter reading across the

incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and

correct the external wiring. (This is a common problem

when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and

corrected if necessary, reconnect the external thermostat

circuit wires to the connection board.

Inspect/fill condensate system

Inspect/check condensate lines and fittings

1. Inspect the condensate drain line, condensate PVC fittings

and condensate trap.

Fill condensate trap with water

1. Remove the bezel as depicted in FIG. 8-1 on page 50 of this

manual.

2. Remove the PVC cap retaining screw from the PVC cap

(FIG. 10-1).

3. Remove the 2 inch PVC cap with the switch located at the

top of the trap (FIG. 10-1).

4. Fill with fresh water until the water begins to pour out of the

drain.

5. Replace the cap. Press the cap onto the trap until the cap

makes contact with the drain.

6. Replace the retaining screw.

7. Reinstall bezel.

The condensate trap (FIG. 10-1) must be

filled with water during all times of boiler

operation to avoid flue gas emission from the

condensate drain line. Failure to fill the trap

could result in severe personal injury or

death.

Figure 10-1 Condensate Trap

WARNING

WARNING WARNING

Clean/Inspect Trap Assembly

1. Remove the clean out cap on the bottom of the trap. Let the

condensate and any debris drain out.

2. Refill the trap according to the instructions above.

Installation & Operation Manual

10 Start-up (continued)

Final checks before starting the boiler

Read the Knight Wall Mount Service Manual to

familiarize yourself with SMART SYSTEM control

module operation. Read this manual, page 58 for proper

steps to start boiler.

Verify the boiler and system are full of water and all

system components are correctly set for operation.

Verify the preparation procedures of Section 10, pages 55

and 56 have been completed.

Fill the vent condensate trap with water (removing the

retaining screw in order to remove the 2 inch PVC cap

with the switch located at the top of the trap). Replace

the cap. Press the cap onto the trap until the cap makes

contact with the drain. Replace the retaining screw.

Verify electrical connections are correct and securely

attached.

Inspect vent piping and air piping for signs of

deterioration from corrosion, physical damage or

sagging. Verify air piping and vent piping are intact and

correctly installed per this manual.

Start the boiler

1. Read and follow the Operating instructions in FIG. 10-2,

page 58.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch

off?

2. Is boiler water temperature above 200°F?

3. Is thermostat set below room temperature?

4. Is gas turned on at meter or boiler?

5. Is incoming gas pressure less than 4 inches w.c.?

If none of the above corrects the problem, refer to the

Troubleshooting Section of the Knight Wall Mount Service

Manual.

Check system and boiler

Check water piping

1. Check system piping for leaks. If found, shut down the

boiler and repair immediately. (See WARNINGS on

pages 55 and 56 (startup) regarding failure to repair

leaks.)

2. Vent any remaining air from the system using manual

vents. Air in the system will interfere with circulation and

cause heat distribution problems and noise.

Check vent piping and air piping

1. Check for gastight seal at every connection, seam of air

piping, and vent piping.

Venting system must be sealed gastight to

prevent flue gas spillage and carbon

monoxide emissions, which will result in

severe personal injury or death.

Check gas piping

1. Check around the boiler for gas odor following the

procedure on page 46 of this manual (connecting gas supply

piping).

If you discover evidence of any gas leak, shut

down the boiler at once. Find the leak source

with a bubble test and repair immediately.

Do not start the boiler again until corrected.

Failure to comply could result in severe

personal injury, death, or substantial

property damage.

Propane boilers – verify conversion

1. Verify propane conversion has been completed per the

Propane Conversion instructions.

DO NOT adjust or attempt to measure gas

valve outlet pressure. The gas valve is

factory-set for the correct outlet pressure.

This setting is suitable for natural gas and

propane, requiring no field adjustment.

Attempting to alter or measure the gas valve

outlet pressure could result in damage to the

valve, causing potential severe personal

injury, death, or substantial property

damage.

Check flame and combustion

1. Turn the main power off to the boiler.

2. Remove the flue temperature sensor from the flue pipe

connection. Note: Combustion measurements will be

made at this point.

3. Turn the main power on to the boiler.

WARNING

WARNING Knight wall mount boilers are typically

shipped ready to fire on natural gas. Check

boiler rating plate to determine which fuel

the boiler is set for. If set to natural gas, it

may be converted to LP by installing an

orifice (see page 13). In order to operate on

LP gas, an orifice MUST BE installed.

Failure to comply could result in severe

personal injury, death, or substantial

property damage.

10 Start-up

Figure 10-2 Operating Instructions

Installation & Operation Manual

Please note that the brackets ([]) denote

screen status.

NOTICE

4. Place the boiler into the active position by pressing the

RIGHT SELECT [ON] key (FIG. 11-1, page 67).

5. Locate the pinhole button below the RESET button on the

display board (FIG. 11-1). Insert a thin wire (such as a

paper clip) into the hole and press the button once and

hold for 5 seconds to place the boiler into Service Mode.

In Service Mode the boiler will fire at ignition speed and

will then modulate up to full fire.

6. Insert the probe from a combustion analyzer into the hole

left by the removal of the flue temperature sensor.

7. Once the boiler has modulated up to full fire, measure the

combustion. The values should be in the range listed in

Table 10A below. The CO levels should be less than

150 ppm for a properly installed unit.

If the combustion is not within the specified range,

reference the Troubleshooting Section of the Knight Wall

Mount Service Manual for possible causes and corrective

actions.

10 Start-up (continued)

Check flame and combustion (continued) Set space heating operation

Determine controlling sensor

For space heating systems, the temperature control can be based

on one of three sensors; the inlet, outlet, or system supply

sensor. The SMART SYSTEM control is programmed at the

factory to control the temperature of the outlet sensor. The

control will automatically switch to the system supply sensor

once it is connected. If it is desired to base the temperature

control on the inlet sensor, the appropriate parameter must be

changed in the control. See the Knight Wall Mount Service

Manual for a detailed explanation of this procedure.

Verify space heat circulator mode

The Space Heating Mode controls both the system (primary)

pump (if connected), and the boiler (secondary) pump. When

the SMART SYSTEM control receives a space heating call for

heat, it turns on the system pump. If the boiler is not heating an

indirect DHW (Domestic Hot Water) tank, and the set point is

not met, it also turns on the boiler pump. After the space

heating call for heat ends, the system pump continues to run for

a short period of time. The system pump can be programmed

to run continuously, except during outdoor shutdown. If the

boiler pump was running, it continues to run for a short period

of time as well. These pump delays are factory set to 30 seconds.

If different delays are desired, the appropriate parameters in the

control must be changed. See the Knight Wall Mount Service

Manual for a detailed explanation of this procedure.

Adjust set point temperature

Table 10A Flue Products Chart

8. Once the combustion analysis is complete, test the

safety shutoff device by turning the manual shutoff

switch to the OFF position and ensuring that the boiler

shuts down and registers an alarm. Turn the manual

shutoff switch to the ON position, reset the control, and

return to Service Mode.

9. Turn the main power off to the boiler and replace the

flue temperature sensor into the flue pipe connection.

10. Place the boiler back into normal operation.

You must replace the flue gas temperature

sensor to prevent flue gas spillage into the

room. Failure to comply could result in

severe personal injury, death, or

substantial property damage.

WARNING

Natural Gas Propane

8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%

Please note that the brackets ([]) denote

screen status.

NOTICE

The NAVIGATION dial may be used during normal operation

to adjust the space heating and tank set point temperatures.

1. From the Status Screen press the NAVIGATION dial.

2. Turn the NAVIGATION dial counterclockwise to select the

appropriate set point.

3. Press the NAVIGATION dial to adjust the temperature.

4. Once the desired temperature is displayed, press the

RIGHT SELECT [SAVE] key.

5. If necessary repeat Steps 3 and 4 to make adjustments to

additional set points.

6. Press the RIGHT SELECT [HOME[ key to upload the

changes.

7. If the RIGHT SELECT [SAVE] key is not pressed, the

new settings will be discarded.

Installation & Operation Manual

10 Start-up

Set domestic hot water (DHW) operation

Verify DHW mode

There are two (2) modes of operation for DHW. In Normal

Mode, when a DHW demand begins, the control will start the

DHW pump, turn off the boiler pump (if running), and

modulate to bring the outlet temperature to the DHW boiler

set point. The maximum firing rate may be limited in this

mode if desired.

In Zone Mode it is assumed that the indirect DHW tank is

piped as a zone on the primary loop. When a DHW demand

begins, the control will turn on the DHW pump output, and

raise the system temperature set point to the DHW boiler set

point (if higher). The system pump and the boiler pump will

be turned on. In this mode, any low temperature zones (such

as radiant heating) may need additional controls to limit the

water temperature sent to those zones.

Set DHW target temperature

When in the DHW Mode, the control will modulate to

maintain the boiler outlet temperature or system supply

temperature to a set point. This set point is set at the factory

to 180°F. If a different set point is desired, the appropriate

parameter in the control must be changed. See the Knight

Wall Mount Service Manual for a detailed explanation of this

procedure.

Set maximum DHW fan speed

If the rated input of the indirect tank is less than the

maximum output of the boiler, change the maximum DHW

fan speed setting to limit the boiler output accordingly, see the

Knight Wall Mount Service Manual for a detailed explanation

of this procedure.

NOTICE The internal clock does not adjust for

Daylight Savings Time and therefore, will

require a manual adjustment.

7. Turn the NAVIGATION dial to adjust the minutes. Press

the NAVIGATION dial.

8. Turn the NAVIGATION dial to adjust the month. Press the

NAVIGATION dial.

9. Turn the NAVIGATION dial to adjust the date. Press the

NAVIGATION dial.

10. Turn the NAVIGATION dial to adjust the year. Press the

RIGHT SELECT [SAVE] key.

11. Press the RIGHT SELECT [HOME] key.

Please note that the brackets ([]) denote

screen status.

NOTICE

Configuration of the cascade

Please note that the brackets ([]) denote

screen status.

NOTICE

When installed in a Cascade system, the individual controls

must be programmed for cascade operation. This is

accomplished by accessing the control parameters.

Press the [MENU] key for at least five (5) seconds. Input the

Installer code as described in the Knight Wall Mount Service

Manual. Once the control parameters have been accessed, use

the NAVIGATION dial to select the Control Mode parameters.

Press the NAVIGATION dial to access these parameters.

Rotate the NAVIGATION dial to select the parameter Cascade

Address. Press the NAVIGATION dial to access this parameter.

Each appliance in the Cascade system must be programmed

with its own address. The boiler designated as the Leader will

have an address of 0. The remaining boilers in the Cascade will

be Members and have addresses from 1 - 7. Rotate the

NAVIGATION dial to select the appropriate address. Press the

RIGHT SELECT [SAVE] key. If installing the boilers in an

existing system, the new boilers should be programmed as the

Leader and/or the higher number addresses.

Press the RIGHT SELECT [HOME] key to upload the address

into the control. Repeat this procedure for all boilers in the

Cascade, designating the Leader control and the Member

controls.

Set clock

The SMART SYSTEM control has a built-in clock that it uses

for its night setback feature and for logging events. This clock

must be set when the boiler is installed, and anytime the

boiler has been powered off for more than 4 hours. Use the

following procedure to set the clock:

1. Press and hold the LEFT SELECT [MENU] key for at

least 5 seconds.

2. The display changes to read [PASSWORD],

with four (4) zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and

date and temperature unit.

5. Press the NAVIGATION dial twice.

6. Turn the NAVIGATION dial to adjust the hours. Press

the NAVIGATION dial.

Installation & Operation Manual

11 Operating information

General

How the boiler operates

The Knight wall mount boiler uses an advanced stainless steel

heat exchanger and electronic control module that allows

fully condensing operation. The blower pulls in air and

pushes flue products out of the boiler through the heat

exchanger and flue piping. The control module regulates

blower speed to control the boiler firing rate. The gas valve

senses the amount of air flowing into the boiler and allows

only the right amount of gas to flow.

How the control module operates

The SMART SYSTEM control module receives inputs from

boiler sensors and external devices. The control module

activates and controls the blower and gas valve to regulate

heat input and switches the boiler, Domestic Hot Water

(DHW), and system pumps on and off as needed. The user

programs the module to meet system needs by adjusting

control parameters. These parameters set operating

temperatures and boiler operating modes. Boiler operation

can be based on boiler outlet water temperature, boiler inlet

water temperature, system temperature, a 0 - 10V signal, or

Modbus, depending on the parameter settings.

Control inputs and outputs

Room thermostat

There are three (3) thermostat connections available on this

control. These inputs tell the boiler to provide water for space

heating. Each thermostat connection has its own set point

and outdoor air reset curve. When multiple thermostats have

a call for heat the control will give priority to the demand

with the highest set point.

Example: Assume that both Room Thermostat 1 and Room

Thermostat 2 have a call for heat. RoomThermostat 1 has a

set point of 110°F. Room Thermostat 2 has a set point of

140°F. The boiler will regulate the system temperature to

140°F until Room Thermostat 2 has been satisfied. Once

Room Thermostat 2 has been satisified the boiler will provide

110°F water to the system.

0 - 10V input (set point or power)

The Knight wall mount boiler can be controlled by a Building

Management System (BMS) using a 0 - 10 vdc signal. The

control can be configured by the installer to use this signal to

either control set point or firing rate.

The Knight wall mount boiler can also be programmed to

accept a call for heat from a 0 - 10V signal, reference the

Knight Wall Mount Service Manual for a detailed explanation

of this procedure.

DHW priority

The SMART SYSTEM control allows the connection of a DHW

thermostat or tank sensor to the low voltage connection board.

When a tank sensor is connected, the DHW thermostat input is

ignored.

DHW / space heating (SH) cycling

If a DHW call for heat is received while a space heating call is in

progress and the DHW is in Normal Mode, the control will start

the DHW pump and shut the boiler pump off. The system

pump will remain on. If the space heating call is still active while

the DHW call is in operation, the control will wait for 30

minutes (time adjustable by installer) then it will switch back to

the space heating demand. There is a timer to switch from space

heating to DHW and a timer to switch from DHW to space

heating. The control will switch back and forth until one of the

heat demands end.

Programmable controlling sensor

The control module is programmed to use the outlet sensor as

the control sensor by default. If a system supply sensor is

connected, the control automatically uses it as the control

sensor. The control sensor can be changed by the installer to the

inlet sensor. If the inlet sensor is chosen as the controlling

sensor, it is recommended that the system supply sensor be

installed in order to provide the best control of the inlet

temperature.

Anti-cycling

After the burner turns off, the control will delay the next burner

cycle for a set time period (time is adjustable by the installer).

The time delay will be bypassed if the inlet water temperature

drops too far during the delay.

Boiler and system pump control

The boiler pump will run whenever the burner is firing, unless

the DHW is programmed for Normal Mode and the boiler is

heating the DHW tank. The boiler pump will run during Freeze

Protection Mode as well. It will continue to run for a short time

after the burner turns off or the Freeze Protection Mode ends.

The system pump will run whenever there is a space heating call

for heat, or the boiler goes into Freeze Protection Mode. It will

continue to run for a short time after the end of the heat

demand or the Freeze Protection Mode. The system pump can

be programmed to run continuously if desired. In either case, it

will not run during outdoor shutdown.

Temperature control

Modulation

The Knight wall mount boiler is capable of modulating its firing

rate from a minimum of 20% to a maximum of 100%. The

firing rate is dictated by the call for heat (i.e., space heating or

domestic hot water), the heating load, ramp delay (if enabled),

and various other temperature limitations.

CAUTION When multiple temperature loops are

used, thermostatic mixing valves are

required for the protection of any low

temperature loops.

Installation & Operation Manual

11 Operating information

Ramp delay

For systems with lower flow, the SMART SYSTEM can limit

the firing rate (when enabled) when a space heating call for

heat starts, or when switching from a DHW call for heat to a

space heating call for heat. There are six (6) limits that can be

programmed, as well as six (6) time intervals corresponding

to each limit. The sixth limit will also limit the firing rate for

the rest of the call for heat.

Gradient limiting

If during operation of the boiler the outlet water temperature

is rising too quickly, the control will reduce the firing rate to

its lowest setting.

Outdoor air reset

With the outdoor air sensor connected, the control module

will calculate the set points of the three (3) space heating

demands based on the programmed reset curves. The

installer can change the slope of the reset curves by several

adjustable parameters. The user can limit the maximum set

point for the system using the space heating set points.

Boost function

If outdoor air reset is active, and any space heating demand

has been active continuously for a set period of time (time

adjustable by installer) and there has been no DHW demands,

the control will increase the set point of that demand by a

fixed number of degrees (adjustable by installer). This

process will continue until the space heating demand ends,

the set point reaches the programmed set point or a

maximum of 20 increases has occurred. Once the system heat

demand is satisfied, the set point will revert to the value

determined by the reset curve.

Night setback

The controller may be programmed to reduce the space

heating and DHW set points during certain times each week.

Seven different start and stop times may be programmed for

the space heating setback and seven start and stop times for

the DHW setback.

Flame current support

To prevent nuisance shutdowns when the boiler is firing at

minimum rates, the control will increase the firing rate when

the flame signal drops too low.

Protection features

Outlet temperature, flue temperature, and

temperature rise limiting

The outlet temperature is monitored by the boiler outlet

temperature sensor. When the outlet temperature exceeds

185°F, the unit will reduce the fan speed. If the outlet water

temperature exceeds 195°F the control will shut the unit down

until it cools off.

The control module monitors the flue temperature by a sensor

located in the flue exhaust. If the flue temperature exceeds

215°F the control will reduce the maximum fan speed. If the

flue temperature exceeds 240°F the control will shut the unit

down. The unit will restart automatically once the flue

temperature drops 25°F and the minimum off time has expired.

The control monitors the temperature difference between the

inlet and the outlet sensor. If this difference exceeds 55°F the

control will reduce the maximum fan speed. If the temperature

difference exceeds 60°F the control will shut the unit down. The

unit will restart automatically once the temperature difference

has dropped below 55°F and the minimum off time has expired.

Freeze protection

DO NOT install the boiler in a room likely to freeze.

The following integral feature of the SMART SYSTEM control

module provides some protection for the boiler only -- not for

the system.

• The SMART SYSTEM control module provides

freeze-up protection as follows when the boiler

water temperature drops below 45°F:

• Below 45°F, the boiler and system pumps operate

constantly.

• Below 37°F, the boiler turns on.

• Boiler and pumps turn off if boiler water

temperature rises above 45°F.

• Lower temperatures may be programmed for

systems with anti-freeze solutions.

This feature of the SMART SYSTEM control

module does not eliminate the possibility of

freezing. The installation must still use

recognized design, installation and

maintenance practice to prevent freeze

potential for the boiler and system.

CAUTION

NOTICE When system return temperatures are

maintained below the dew point,

condensation will form on the inside of the

boiler jacket causing some internal sheet

metal components to rust.

Installation & Operation Manual

11 Operating information (continued)

Monitor external limits

Connections are provided on the connection board for

external limits such as flow switch, low water cutoff, gas

pressure switches, and a louver proving switch. The SMART

SYSTEM will shut off the burner and inhibit relighting

whenever any of these external limits open.

Run-time and alarm outputs

The boiler provides dry contacts for indicating when the

boiler is running, and when it is unable to operate.

Run-time and cycle counting

The control uses two timers to monitor the total hours of

burner operation. One timer monitors the time the boiler is

firing in the Space Heating Mode. The other timer monitors

the time the boiler is in the DHW Mode.

The control uses two (2) ignition counters to monitor the

amount of boiler cycles. The first counter counts all ignitions

of the control. The second counter counts only ignition

attempts that have failed.

Service reminder

The control can be programmed for service reminder

notification. This notification will become active when either

a set time frame has expired, or a set amount of running

hours or cycles has expired (all adjustable by the installer).

The display will show a Maintenance Required screen. The

service reminder notification can be reset or disabled by the

installer.

The time dependent feature has been disabled by the

manufacturer. To enable this feature change parameter K1 to

the desired time range, reference the Knight Wall Mount

Service Manual for details regarding parameters.

Error logging

The control will hold in memory the last 10 lockouts as well

as the last 10 blockings. The date and time of the occurrence

will be recorded as well. Only the 10 most current

occurrences of each will be held in memory.

Boiler temperature regulation

Operating temperature (target)

The SMART SYSTEM control module senses water

temperature and regulates boiler firing and firing rate to

achieve a target temperature. The target temperature can be

set between 32°F and 190°F.

• Target temperature is fixed when the outdoor

sensor is not installed.

• Target temperature is calculated as described in

this section under “Outdoor Reset Operation” and

“Target Temperature Boost” when the outdoor

sensor is connected.

High limit operations

The Knight wall mount is equipped with adjustable automatic

reset and manual reset high limits. The automatic reset high

limit has a maximum set point of 200°F and the manual reset

high limit has a maximum set point of 210°F.

When the outlet temperature exceeds 200°F, the automatic high

limit action occurs. The boiler shuts down until the outlet

water temperature cools below 190°F, and a 60 second timer has

expired. If the outlet temperature continues to increase, the

manual reset high limit action will occur at 210°F.

High limit test procedure

1. Turn ON the main power to the boiler by placing the

ON/OFF switch in the ON position.

2. If boiler status reads [SHUTDOWN] place the boiler into

the active position by pressing the RIGHT SELECT [ON]

key.

3. Locate the pinhole (SERVICE button) below the RESET

button on the display board. Insert a thin wire (such as a

paper clip) into the hole and press the button once, hold

for five (5) seconds to place the boiler into Service Mode.

In Service Mode the boiler will fire at ignition speed and

will then modulate up to full fire.

4. From the Status Screen, press the NAVIGATION dial to

access the Set Points Screen.

5. Press the LEFT SELECT [LIMITS] key.

6. Select the manual reset high limit (MRHL) by pressing the

NAVIGATION dial.

7. Decrease the set point of the MRHL below the outlet

temperature by turning the NAVIGATION dial

counterclockwise.

8. Press the RIGHT SELECT [SAVE] key.

9. Press the RIGHT SELECT [HOME] key.

10. The new parameters will upload to the control and the

MRHL will function causing boiler shutdown and

[LOCKOUT] to be displayed.

11. Press the RESET button to clear the lockout.

12. Repeat Steps 4, 5, and 6.

13. Set the MRHL to the appropriate set point by turning the

NAVIGATION dial clockwise.

14. Repeat Steps 8 and 9.

Low water cutoff protection

1. The SMART SYSTEM control module uses temperature

sensing of both supply and return areas of the heat

exchanger. If the flow rate is too low or the outlet

temperature too high, the control module modulates and

shuts the boiler down. This ensures boiler shutdown in the

event of low water or low flow conditions.

2. Some codes and jurisdiction may accept these integral

features of the control in lieu of requiring an additional

limit control or low water cutoff. Consult local jurisdiction

to determine. A low water cutoff is available from the

factory (WTR20009).

Please note that the brackets ([]) denote

screen status.

NOTICE

Installation & Operation Manual

11 Operating information

DHW, Night Setback, and Ramp Delay operation with

cascade

For normal mode DHW operation any boiler(s) in the Cascade

can be selected to provide heat for a DHW call. Select a boiler to

be designated as the DHW boiler. Connect the DHW thermostat

or sensor to the terminals on the Low Voltage Connection Board

marked for the corresponding device. When the boiler receives a

DHW call, the Leader control will take that boiler out of the

Cascade sequence. If another boiler is available, the Leader will

start it up to take its place.

The DHW boiler will adjust its set point to the programmed

DHW set point and will adjust its firing rate to maintain this.

Once the DHW call has been satisfied, the Leader control will

place that boiler back into the Cascade sequence.

Switching of the boiler between DHW operation and SH

operation when there is a call for both does not occur in Cascade

Mode.

When DHW is programmed for Zone Mode, connect the DHW

thermostat or tank sensor to the Leader boiler. When a DHW

call is received, the Leader will modulate the entire Cascade to

bring the system supply temperature up to the DHW boiler set

point (if higher).

Night Setback operation of the boilers within the Cascade is

available. Programming of the Night Setback will be done

through the Leader boiler. Refer to the Knight Wall Mount

Service manual for information regarding Night Setback.

Ramp Delay operation of the boilers as described in the Knight

Wall Mount Service Manual is not active when the boilers are

part of a Cascade system.

Sequence of the cascade

To equalize the run time of all boilers on the Cascade, the firing

sequence will automatically be changed at set intervals.

For the first 24 hours after initializing the Cascade, the sequence

will be changed every hour. After that the sequence will be

changed once every 24 hours. The switching on/off sequence

will be as follows:

DAY SWITCHING ON SEQUENCE

Day 1 L-M1-M2-M3-M4-M5-M6-M7

Day 1 + 1 hour M1-M2-M3-M4-M5-M6-M7-L

Day 1 + 2 hours M2-M3-M4-M5-M6-M7-L-M1

If a boiler is used to heat an indirect DHW tank, it will

automatically be given the lowest priority.

Cascade

When multiple boilers are installed, they can be wired

together in a cascade sequence. A maximum of eight boilers

can be controlled from a single control. In this application

one boiler would be designated as the Leader control and all

others would be designated as Member controls. If installing

the boilers in an existing system, the new boilers should be

programmed as the Leader and/or the higher number

addresses. The Leader control can be programmed to use

Lead/Lag or Efficiency Optimization control methods.

Once the Leader boiler receives a call for heat from a room

thermostat, BMS, or Modbus, the control will determine what

the set point will be. If outdoor air reset is desired, connect the

outdoor air sensor to the terminals on the Low Voltage

Connection Board on the Leader boiler. The set point will be

calculated based on the programmed reset curve parameters.

See the Knight Wall Mount Service Manual to program the

reset curve. If outdoor air reset is not desired, do not connect

the outdoor air sensor. A fixed temperature set point can be

programmed into the control. See page 59 of this manual to

program the set point.

If the water temperature at the system supply sensor is less

than the set point + the turn-off offset - the off-on

differential, then the control will initiate a call for heat on the

Cascade (see the Knight Wall Mount Service Manual for an

explanation of the offset and differential). The Leader will

energize the lead boiler on the Cascade. For a new startup this

will be the Leader boiler.

Outdoor reset operation, if used

Target temperature with outdoor reset

This feature improves the system’s efficiency as the outdoor

temperature warms up.

See the Knight Wall Mount Service Manual to change the

settings.

Reset curve

The reset curve looks at outdoor air temperature and adjusts

the set point.

Installation & Operation Manual

11 Operating information (continued)

Sequence of operation

OPERATION DISPLAY

1. Upon a call for heat, the gas pressure switch(es) must be closed.

2. Once the gas pressure switch(es) are closed, the control turns

on the appropriate pumps (system and boiler pumps for space

heating, DHW pump for DHW).

The flow switch and/or LWCO must close.

3. The control turns on power to the louver relay.

The louver proving switch, air pressure switch, and blocked

drain switch must close.

4. The control starts a 15 second prepurge cycle by initiating the

blower.

5. The control starts a 4 second trial for ignition by firing the spark

electrode and opening the gas valve.

6. If flame is not detected within 1 second after the sparking ends,

the control will perform a 10 second post-purge, then start

another prepurge cycle and try to light the burner again. The

control will perform a total of 4 attempts before locking out.

7. If flame is detected, it holds the firing rate steady for 5 seconds

to let the flame stabilize, then it begins to modulate the firing rate

based on a set point or some other command (such as a 0-10V

BMS signal).

Installation & Operation Manual

11 Operating information

Sequence of operation (continued)

Access modes

User

The user can adjust space heating and tank target

temperatures by pressing the NAVIGATION dial when

“SETPOINTS” is flashing at the bottom of the display. The

date and time, and the temperature units can also be changed

(see page 60).

Installer

Most parameters are available only to the installer, accessible

by entering the installer password, see the Knight Wall Mount

Service Manual.

Saving parameters (reference the Parameter Table in

the Knight Wall Mount Service Manual)

To save parameters and exit programming:

Press the RIGHT SELECT [SAVE] key and then press the

RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

Press the RIGHT SELECT [SAVE] key 1 time to return to the

parameter listings; press again to return to the menu listings.

Remember to press the RIGHT SELECT [HOME] key when

finished programming in order to save the changes made.

See the Knight Wall Mount Service Manual for a detailed

description of parameters and access modes.

OPERATION DISPLAY

8. If the space heating call for heat is active, and the tank thermostat

or sensor starts a DHW call for heat, the boiler will switch to the

DHW mode. If programmed for normal DHW operation (not as a

zone), the DHW pump will turn on first, then the boiler pump will

turn off 2 seconds later.

This will divert the boiler’s outlet water from the heating system

and send it to the tank coil instead.

The control will then modulate to maintain the outlet temperature

9. If the boiler is not part of a Cascade, and both the space heating

and DHW calls for heat remain active long enough, the boiler will

switch back and forth between the two heating modes until one of

them is satisfied.

10. Once both calls for heat are satisfied, the control will turn off the

burner. The blower will continue to run during a 10 second

postpurge.

11. Any pumps that are running will continue to run for their

respective pump delay times before turning off, unless

programmed to remain on continuously.

A 60 second anti-cycle period will start, which will delay any new

call for heat until it times out.

12. In Standby, ready to start a new cycle.

Please note that the brackets ([]) denote

screen status.

NOTICE

Installation & Operation Manual

Knight wall mount boiler control module

NAVIGATION DIAL

Figure 11-1 Control Panel

Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.

11 Operating information (continued)

The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the

NAVIGATION dial (in the center):

MENU = Left SELECT Key

SETPOINTS = NAVIGATION Dial - Pressing Down

SHDN = Right SELECT Key

Installation & Operation Manual

11 Operating information

Status Display Screens

Section Display Description

(Boiler Status

Bar)

STANDBY The unit has not received a call for heat from a remote thermostat nor

has it received a call for heat from a DHW thermostat.

START The unit has begun a burn cycle and is checking all safety circuits.

PREPURGE The unit has initiated a 10 second purge period on a call for heat.

IGNITION The unit has begun a 4 second spark period to ignite the main burner.

The unit has fired and is running at the displayed percentage.

POSTPURGE

The call for heat has been satisfied and the unit runs the fan for an

additional 10 seconds to clear the combustion chamber and vent

system of residual flue products.

SHUTDOWN The unit has been placed in the OFF position.

The controlled temperature has exceeded its set point and its offset.

BLOCKED The unit has detected a condition that has temporarily interrupted

the current call for heat.

(Call for Heat

Indicators)

Room Thermostat 1 has a call for heat.

Room Thermostat 2 has a call for heat.

Room Thermostat 3 has a call for heat.

The tank thermostat or sensor has a call for heat.

Indicates which room thermostat demand shows priority.

The unit is being controlled by a 0 - 10V BMS signal.

The member unit is supplying heat while in Cascade Mode.

(BOILER

STATUS)

(OPERATIONAL

INFORMATION)

(LEFT SELECT

KEY)

(RIGHT SELECT KEY)

(NAVIGATION DIAL)

(CALL FOR

HEAT)

Figure 11-2 Status Display Screen

Installation & Operation Manual

Status Display Screens (cont’d)

Section Display Description

(Operational

Information)

SYSTEM: The temperature read by the system supply sensor (if connected).

TANK: The temperature read by the tank sensor (if connected).

OUTDOOR: The temperature read by the outdoor sensor (if connected).

INLET TEMP: The temperature read at the inlet to the heat exchanger.

OUTLET TEMP: The temperature read at the outlet of the heat exchanger.

DELTA T: The temperature difference between the inlet and the outlet of the

heat exchanger.

FLUE TEMP: The temperature read by the flue sensor.

FLAME CURRENT: The current measured by the flame sense circuit.

FAN SPEED: The speed of the combustion blower.

BOILER PUMP: The status of the boiler pump output.

SYSTEM PUMP: The status of the system pump output.

DHW PUMP: The status of the DHW pump output.

BMS VOLTAGE: The voltage received from a BMS system.

BLR PUMP OUTPUT: The speed signal sent to a variable speed boiler pump in percent.

SYS PUMP INPUT: The speed signal received from a variable speed system pump control.

RATE OUTPUT: A 0 - 10V signal indicating the firing rate of the boiler.

SH RUN HOURS: The total hours of operation in the Space Heating Mode.

SH CYCLES: The total burner cycles in the Space Heating Mode.

DHW RUN HOURS: The total hours of operation in the DHW Mode.

DHW CYCLES: The total burner cycles in the DHW Mode.

LAST 10 FAULTS NO:* The last 10 lockouts.

(LEFT SELECT

key function)

MENU Press and hold the LEFT SELECT key for 5 seconds to enter the Menu

Screen.

EXIT Press the LEFT SELECT key to exit the current screen or setting.

YES Press the LEFT SELECT key to confirm that the boiler needs to

shutdown.

LIMITS Press the LEFT SELECT key to enter the screen that allows you to

adjust the limit settings.

HOME Press the LEFT SELECT key to return to the Status Screen and upload

parameter changes.

11 Operating information (continued)

Installation & Operation Manual

11 Operating information

Status Display Screens (cont’d)

Section Display Description

(NAVIGATION

dial function)

Turning the NAVIGATION dial will select the next or previous Status

Screen.

Pressing the NAVIGATION dial will show the next fault, NSB (Night

Setback) trigger, or ramp delay setting.

Pressing the NAVIGATION dial will select the setting indicated by the

cursor.

Pressing the NAVIGATION dial will display the Set Points Screen.

Turning the NAVIGATION dial will move the cursor up or down.

Turning the NAVIGATION dial will increase or decrease the current

setting.

(RIGHT SELECT

key function)

SHDN Press the RIGHT SELECT key to turn the boiler OFF.

ON Press the RIGHT SELECT key to turn the boiler ON.

NO Press the RIGHT SELECT key to cancel the shutdown operation.

SAVE Press the RIGHT SELECT key to save the current change.

HOME Press the RIGHT SELECT key to return to the Status Screen and

upload parameter changes.

Installation & Operation Manual

Maintenance and annual startup

Table 12A Service and Maintenance Schedules

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if

necessary;

• Clean condensate trap and fill with fresh

water

• Check for leaks (water, gas, flue,

condensate)

• Verify flue and air lines in good condition

and sealed tight

• Check system water pressure/system

piping/expansion tank

• Check control settings

• Check ignition and flame sense

electrodes (sand off any deposits; clean

and reposition)

• Check wiring and connections

• Perform start-up checkout and

performance verification per Section 10

of this manual.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at

high fire)

• Clean the heat exchanger if flue

temperature is more than 54°F above

return water temperature.

If combustion or performance

indicate need:

• Clean heat exchanger

• Remove and clean burner using

compressed air only

• Clean the blower wheel

ANNUAL START-UP

Owner maintenance

(see the Knight Wall Mount User’s Information

Manual for instructions)

Daily

• Check boiler area

• Check pressure/temperature

gauge

Monthly

• Check vent piping

• Check air piping

• Check air and vent termination

screens

• Check relief valve

• Check condensate drain system

• Check air vents

Periodically

• Test low water cutoff (if used)

• Reset button (low water cutoff)

Every

6 months

• Check boiler piping (gas and

water) for leaks

• Operate relief valve

End

of season

months

• Shut boiler down (unless boiler

used for domestic hot water)

12 Maintenance

Installation & Operation Manual

12 Maintenance

Follow the Service and maintenance procedures given throughout this manual and in component literature

shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler

or system. Failure to follow the directions in this manual and component literature could result in severe

personal injury, death, or substantial property damage.

The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance

and care of the boiler designated in Table 12A and explained on the following pages must be performed to

assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could

result in equipment failure.

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as

noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,

causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct

before proceeding.

Inspect boiler area

1. Verify that boiler area is free of any combustible

materials, gasoline and other flammable vapors and

liquids.

2. Verify that air intake area is free of any of the

contaminants listed in Section 1 of this manual. If any of

these are present in the boiler intake air vicinity, they

must be removed. If they cannot be removed, reinstall

the air and vent lines per this manual and the Knight Wall

Mount Service Manual.

Inspect boiler interior

1. Remove the front access cover and inspect the interior of

the boiler.

2. Vacuum any sediment from inside the boiler and

components. Remove any obstructions.

Clean condensate trap

1. Remove the clean out cap on the bottom of the trap. Let

the condensate and any debris drain out.

2. Fill with fresh water until the water begins to pour out of

the drain.

3. Replace the clean out cap and resume operation.

Eliminate all system or boiler leaks.

Continual fresh makeup water will reduce

boiler life. Minerals can build up in

sections, reducing heat transfer, overheating

heat exchanger, and causing heat exchanger

failure. Leaking water may also cause severe

property damage.

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems

found.

3. Check gas line using the procedure found in Section 7 -

Gas Connections.

Check all piping for leaks

The condensate trap must be filled with

water during all times of boiler operation to

avoid flue gas emission from the condensate

drain line. Failure to fill the trap could

result in severe personal injury or death.

WARNING

Figure 12-1 Condensate Trap

Flue vent system and air piping

1. Visually inspect the entire flue gas venting system and air

piping for blockage, deterioration or leakage. Repair any

joints that show signs of leakage. Verify that air inlet pipe is

connected and properly sealed.

2. Verify that boiler vent discharge and air intake are clean

and free of obstructions.

Failure to inspect for the above conditions

and have them repaired can result in severe

personal injury or death.

WARNING

Check water system

1. Verify all system components are correctly installed and

operational.

2. Check the cold fill pressure for the system. Verify it is

correct (must be a minimum of 12 psi).

3. Watch the system pressure as the boiler heats up (during

testing) to ensure pressure does not rise too high. Excessive

pressure rise indicates expansion tank sizing or

performance problem.

4. Inspect automatic air vents and air separators. Remove air

vent caps and briefly press push valve to flush vent. Replace

caps. Make sure vents do not leak. Replace any leaking

vents.

Installation & Operation Manual

Check expansion tank

1. Expansion tanks provide space for water to move in and

out as the heating system water expands due to

temperature increase or contracts as the water cools.

Tanks may be open, closed or diaphragm or bladder type.

See Section 6 - Hydronic Piping for suggested best

location of expansion tanks and air eliminators.

Check boiler relief valve

1. Inspect the relief valve and lift the lever to verify flow.

Before operating any relief valve, ensure that it is piped

with its discharge in a safe area to avoid severe scald

potential. Read Section 6 - Hydronic Piping before

proceeding further.

Safety relief valves should be re-inspected

AT LEAST ONCE EVERY THREE YEARS,

by a licensed plumbing contractor or

authorized inspection agency, to ensure

that the product has not been affected by

corrosive water conditions and to ensure

that the valve and discharge line have not

been altered or tampered with illegally.

Certain naturally occurring conditions

may corrode the valve or its components

over time, rendering the valve inoperative.

Such conditions are not detectable unless

the valve and its components are

physically removed and inspected. This

inspection must only be conducted by a

plumbing contractor or authorized

inspection agency – not by the owner.

Failure to re-inspect the boiler relief valve

as directed could result in unsafe pressure

buildup, which can result in severe

personal injury, death, or substantial

property damage.

Following installation, the valve lever must

be operated AT LEAST ONCE A YEAR to

ensure that waterways are clear. Certain

naturally occurring mineral deposits may

adhere to the valve, rendering it

inoperative. When manually operating

the lever, water will discharge and

precautions must be taken to avoid

contact with hot water and to avoid water

damage. Before operating lever, check to

see that a discharge line is connected to

this valve directing the flow of hot water

from the valve to a proper place of

disposal. Otherwise severe personal injury

may result. If no water flows, valve is

inoperative. Shut down the boiler until a

new relief valve has been installed.

2. After following the warning directions in this manual, if the

relief valve weeps or will not seat properly, replace the relief

valve. Ensure that the reason for relief valve weeping is the

valve and not over-pressurization of the system due to

expansion tank waterlogging or undersizing.

WARNING

12 Maintenance (continued)

Inspect ignition and flame sense

electrodes

1. Remove the ignition and flame sense electrodes from the

boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/flame

sense electrode using sandpaper. If the electrodes cannot be

cleaned satisfactorily, replace with new ones.

3. Replace ignition/flame sense electrode, making sure gasket is

in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger access

cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not

satisfactory.

Check all boiler wiring

1. Inspect all boiler wiring, making sure wires are in good

condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to

Parameter Mode and check all settings. See Section 1 of the

Knight Wall Mount Service Manual. Adjust settings if

necessary. See Section 1 of the Knight Wall Mount Service

Manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust

if necessary.

Perform start-up and checks

1. Start boiler and perform checks and tests specified in

Section 10 - Start-up.

2. Verify cold fill pressure is correct and that operating

pressure does not go too high.

Check burner flame

1. Inspect flame through observation window.

2. If the flame is unsatisfactory at either high fire or low fire,

turn off boiler and allow boiler to cool down. Remove the

burner and clean it thoroughly using a vacuum cleaner or

compressed air. Do not use compressed air to clean burner

if performed inside a building.

3. Remove the burner, reference FIG. 12-2 (page 74).

4. When replacing the burner, ensure gasket is in good

condition and positioned correctly (FIG. 12-2).

Installation & Operation Manual

12 Maintenance

Figure 12-2 Burner Assembly

Check flame signal

1. At high fire the flame signal shown on the display should

be at least 10 microamps.

2. A lower flame signal may indicate a fouled or damaged

flame sense electrode. If cleaning the flame sense

electrode does not improve, ground wiring is in good

condition, and ground continuity is satisfactory, replace

the flame sense electrode.

3. See Section 3 - Troubleshooting of the Knight Wall Mount

Service Manual for other procedures to deal with low

flame signal.

Review with owner

1. Review the Knight Wall Mount User’s Information

Manual with the owner.

2. Emphasize the need to perform the maintenance schedule

specified in the Knight Wall Mount User’s Information

Manual (and in this manual as well).

3. Remind the owner of the need to call a licensed contractor

should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown

procedure and to schedule an annual start-up at the

beginning of the next heating season.

Oiled bearing circulators

1. The circulator shipped with the Knight wall mount boiler is

water-lubricated. No oiling is required.

2. Check other circulators in the system. Oil any circulators

requiring oil, following circulator manufacturer’s

instructions. Over-oiling will damage the circulator.

3. Replace the boiler front access cover.

The boiler contains ceramic fiber materials.

Use care when handling these materials per

instructions in the Service Manual. Failure to

comply could result in severe personal

injury.

WARNING

Cleaning boiler heat exchanger

For recommended materials; including brush, appropriate

extension(s), refractory cover, and detailed instructions see

Table 12B - Heat Exchanger Cleaning Kits.

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions

for the boiler in Section 10 - Startup.

• Do not drain the boiler unless it will be exposed to

freezing temperatures. If using freeze prevention fluid

in system, do not drain.

2. Allow time for the boiler to cool to room temperature if it

has been firing.

3. Remove the nuts securing the heat exchanger access cover

to the heat exchanger and set aside.

5. Remove the condensate hose from the heat exchanger end.

Connect a field supplied 3/4" diameter hose to a drain pan.

Using field supplied means, cover the refractory in the back

of the combustion chamber of the heat exchanger.

6. Use a vacuum cleaner to remove any accumulation on the

boiler heating surfaces. Do not use any solvent.

7. Brush the heat exchanger while dry using a nylon bristle

brush. Caution: DO NOT use a metal brush. Re-vacuum

the heat exchanger.

8. Finish cleaning using a clean cloth dampened with warm

water. Rinse out debris with a low pressure water supply.

9. Allow the heat exchanger to thoroughly dry.

10. Remove the field supplied rear refractory cover from the

back of the combustion chamber of the heat exchanger and

reassemble.

11. Close isolation valves on piping to isolate boiler from

system. Attach a hose to the boiler drain and flush boiler

thoroughly with clean water by using purging valves to

allow water to flow through the water make-up line to the

boiler.

12. Perform start-up and check-out procedures in the Check

Flame and Combustion - Section 10 - Startup on pages 57

and 59 of this manual.

13. Replace the access cover and restore boiler to operation.

Table 12B Heat Exchanger Cleaning Kits

Model

Kit

Number

Part

Number

Component

Description

50 - 105 KIT30062

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20085 1/4" x 12" Drill Extension

150 - 210 KIT30063

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20084 3mm Allen Wrench

MSC20086 1/4" x 24" Drill Extension

* Do NOT use a metal brush. Only use the

kit provided brush or an equivalent

replacement nylon brush.

CAUTION

4. Remove the heat exchanger access cover, burner, and

gas/air arm assembly.

Installation & Operation Manual

13 Diagrams

BOX DEPICTS

OPTIONAL ITEMS

LADDER DIAGRAM

LBL20148 REV B

120 VAC

24 VAC

120VAC

TERMINAL STRIP

120V SUPPLY "L"

ON / OFF

SWITCH

X1-6 F2

NEUTRAL

FLOW

CN5-6

CN5-12

CN5-11

X4-2

X4-10

X4-11

INTEGRATED

CONTROL

LOW GAS

PRESSURE

SWITCH

HIGH GAS

PRESSURE

SWITCH

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH CN5-4 X4-4

X2-1

GAS VALVE

RELAY

X5-7

X5-16

X5-8

X5-15

3.15A

TR2

X1-7

FLAME ROD

SPARK

ROD

INTEGRATED CONTROL

GROUND

JUNCTION BOX

CAUTION HIGH VOLTAGE SPARK LEAD

BLOWER

CONNECTION

BOARD

INLET

SENSOR

OPERATING

SENSOR

FLUE

SENSOR

INTEGRATED

CONTROL

RUN-TIME

CONTACTS

RIBBON CABLE

SYSTEM

SENSOR

TANK

SENSOR

OUTDOOR

SENSOR

0-10V

CASCADE A

SHIELD

SILENCING

SWITCH

ALARM

BELL

BMS

CN6 X6

CN3-9 X4-9

CN3-6 X4-6

CN6 X6

CN5-2 X4-6

CN5-9 X4-13

CN5-1 X4-7

CN5-8 X4-14

CN6 X6

HIGH LIMIT

SENSOR

FLUE

SENSOR

X5-4

X5-12

X5-5

X5-13

X5-14

X5-6

0-10V

SYS PUMP

0-10V

BLR PUMP

OUT

0-10V

RATE

OUT

MODBUS A

SHIELD

CN6 X6

CN8-1 X6-1

CN8-2 X6-2

CN8-3 X6-3

X4-1 X9-2

X4-2 X9-1

X4-3 X9-3

PC INTERFACE

S1a

S1b

S3a

S3b

ALARM

CONTACTS

X2-2

NOTES:

1. Where possible, switches are shown without utilities (gas, water or

electricity) connected to the unit. As such, actual switch states may

vary from those shown on diagrams depending upon whether utilities

are connected or a fault condition is present.

2. See wiring diagram for additional notes.

CN5-3 X4-5

X1-1

BLOWER

SYSTEM PUMP

RELAY

DHW PUMP

RELAY

BOILER PUMP

RELAY

24V DC

SUPPLY

.8A

X5-1

X5-9

3.5A

KB 801 ONLY

ROOM

THERMOSTAT 3

LWCO

CONNECTION BOARD

TANK

THERMOSTAT

CN5-13 X4-9

ROOM

THERMOSTAT 2

CN5-7 X4-1

ROOM

THERMOSTAT 1

11 12

SWITCH

CN7-1

CN7-3 CN7-2

CN7-4

CN5-10 X4-12

CN5-14 X4-8

CN5-5

X4-3

CONNECTION BOARD

X1-4

X1-3

X1-2

BOILER

PUMP "L"

DHW

PUMP "L"

SYSTEM

PUMP "L"

BOILER

PUMP

DHW

PUMP

SYSTEM

PUMP

BOILER

PUMP "N"

DHW

PUMP "N"

SYSTEM

PUMP "N"

TERMINAL

STRIP

TERMINAL

STRIP

GND

TERMINAL STRIP

120V SUPPLY "N"

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

BLOCKED

DRAIN SWITCH

X5-2

X5-11

X5-10

AIR PRESSURE

SWITCH

Figure 13-1 Ladder Diagram

Installation & Operation Manual

X1-7

ON/OFF

SWITCH

123 4 5

BLOWER

-T

HIGH LIMIT SENSOR S1b

OPERATING SENSOR S1a

INLET SENSOR S2

FLUE SENSOR S3a

FLUE SENSOR S3b

INTEGRATED

CONTROL

GAS VALVE

@24VAC

SPARK

ROD

TRANSFORMER

TR2

HIGH VOLTAGE SPARK LEAD

CAUTION

FLAME SENSOR

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK

THERMOSTAT

ROOM TSTAT

ZONE CONTROL 3

ROOM TSTAT

ZONE CONTROL 2

ROOM TSTAT

ZONE CONTROL 1

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

CASCADE A

SHIELD

0-10V

BMS

0-10V

SYS PUMP

0-10V

BLR PUMP

OUT

0-10V

RATE

OUT

MODBUS

OPTION

SHIELD

LOW

WATER

CUT-OFF

24 VAC

COM

P/BK

W/R

CN7-1

CN7-2

CN7-3

CN7-4

CN5-1

CN5-8

CN5-2

CN5-9

CN5-3

CN5-10

CN5-11

CN5-4

CN5-5

CN5-14

CN5-12

CN5-6

CN5-13

CN5-7

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

Notes:

1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a

minimum of 105°C. Exceptions: Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead

or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using

diagrams to troubleshoot unit.

WIRING DIAGRAM

LBL20127 REV B

BOX DEPICTS

OPTIONAL ITEMS

X4-7

X4-14

X4-6

X4-13

X4-5

X4-12

X4-11

X4-4

X4-3

X4-8

X4-10

X4-2

X4-9

X4-1

CONNECTION BOARD

CN6 X6

HIGH VOLTAGE

LOW VOLTAGE

120 VAC

X-7

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

MODBUS BOARD

MTR-01

CN8-1

CN8-2

CN8-3

X6-3

X6-2

X6-1

X6-4

X9-1

X9-2

X9-3

X9-4

X4-1

X4-2

X4-3

X4-4

X5-1

X5-2

X1-1

X1-2

X1-3

RBLG

-T

SHIELD

GROUNDING

JUMPER

R/BK

W/BK

1 2

BELL JUMPER

ALARM BELL

SILENCING SWITCH

JUNCTION

BOX

DHW

PUMP

BOILER

PUMP

SYSTEM

PUMP

BOX DEPICTS

OPTIONAL

ITEMS

GND

120V

SUPPLY

X1-3

X1-4

X1-2

X1-5

X1-6

X1-8

X1-1

KB ONLY

AIR PRESSURE

SWITCH

BLOCKED DRAIN

SWITCH

O/BK

Figure 13-2 Wiring Diagram

13 Diagrams

Installation & Operation Manual

Notes

Installation & Operation Manual

Notes

Installation & Operation Manual

Notes

Revision A (ECO #C05747) initial release. Reflects the new model

numbers for the Knight Wall Mount upgrade.

Revision B (ECO #C06188) reflects updates made to the ladder and

wiring diagrams (ECO #C06158).

Revision C (ECO #C06234) reflects changes made to the Service

Reminder feature.

WBII-I-O Rev C

8/10

Lochinvar Knight 51 Users Manual WBII I O Rev C

51 to the manual 7a8581af-a56f-4bde-a000-fca0a5a6ee53

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